Heater for vaporizing liquids

ABSTRACT

A feed gas conditioner.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation in part of U.S. utility patentapplication Ser. Nos. 12/584,610, 12/584,626 and 12/584,640, attorneydocket nos. 032474.000013, 032474.000018 and 032474.000019,respectively, filed on Sep. 9, 2009, Sep. 9, 2009 and Sep. 9, 2009,respectively, which were continuations in part of U.S. utility patentapplication Ser. No. 12/399,811, filed on Mar. 6, 2009, which was acontinuation in part of U.S. utility patent application Ser. No.12/029,957, filed on Feb. 12, 2008, which claimed priority to U.S.provisional patent application Ser. No. 60/889,324, filed on Feb. 12,2007, the disclosures of which are incorporated herein by reference.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic sectional view of an apparatus constructed inaccordance with an exemplary embodiment of the invention.

FIG. 2 is a sectional view of the apparatus of FIG. 1 taken along theline 2-2 of FIG. 1.

FIG. 3 is a sectional view of a portion of an alternate embodiment of anapparatus in accordance with an exemplary embodiment of the invention.

FIG. 4 is a fragmentary cross sectional and schematic illustration of analternate exemplary embodiment of a fuel gas conditioning system.

FIG. 5 is a fragmentary cross sectional illustration of the embodimentof FIG. 4.

FIG. 6 is a fragmentary cross sectional illustration of the embodimentof FIG. 4.

FIG. 7 is a graphical illustration of exemplary experimental resultsobtained during the operation of the embodiment of FIG. 4.

FIG. 8 is a perspective view of an exemplary embodiment of a scissorbaffle assembly.

FIG. 9 is a perspective view of an exemplary embodiment of a scissorbaffle assembly.

FIG. 10 is a perspective view of an exemplary embodiment of a scissorbaffle assembly.

FIG. 11 is a perspective view of an exemplary embodiment of a scissorbaffle assembly.

FIG. 12 is a perspective view of an exemplary embodiment of a scissorbaffle assembly.

FIG. 13 is a perspective view of an embodiment of the invention thatincludes a plurality of scissor baffle assemblies.

FIG. 14 is a side view of an embodiment of the invention that includes aplurality of scissor baffle assemblies.

FIG. 15 is a top view of an embodiment of the invention that includes aplurality of scissor baffle assemblies.

FIG. 16 is a perspective view of an embodiment of the invention thatincludes a plurality of scissor baffle assemblies and heating elements.

FIG. 17 is a side view of an embodiment of the invention that includes aplurality of scissor baffle assemblies and heating elements.

FIG. 18 is a top view of an embodiment of the invention that includes aplurality of scissor baffle assemblies and heating elements.

FIG. 19 is a fragmentary perspective view of an embodiment of theinvention that includes a plurality of scissor baffle assemblies andheating elements.

FIG. 20 is a fragmentary cross sectional and schematic illustration ofan alternate embodiment of a fuel gas conditioning system.

FIG. 21 is a fragmentary perspective view of an experimental embodimentof the fuel gas conditioning system of FIG. 20 that illustrates theoperating temperature of the fluidic material.

FIG. 22 is a fragmentary perspective view of an experimental embodimentof the fuel gas conditioning system of FIG. 20 that illustrates theoperating temperature of the heating elements.

FIG. 23 is a fragmentary perspective view of an experimental embodimentof the fuel gas conditioning system of FIG. 20 that illustrates theoperating pressure of the fluidic material.

FIG. 24 is a fragmentary perspective view of an experimental embodimentof the fuel gas conditioning system of FIG. 20 that illustrates theoperating temperature of the walls of an inner tubular housing thatcontains heating elements.

FIG. 25 is a fragmentary perspective view of an experimental embodimentof the fuel gas conditioning system of FIG. 20 that illustrates theoperating temperature of the heating elements within an inner tubularhousing.

FIG. 26 is a fragmentary perspective view of an experimental embodimentof the fuel gas conditioning system of FIG. 20 that illustrates theoperating pressure of the fluidic material that is heated by heatingelements within an inner tubular housing.

FIG. 27 is a fragmentary perspective view of an experimental embodimentof the fuel gas conditioning system of FIG. 20 that illustrates the flowpaths of the fluidic material that is heated by heating elements withinan inner tubular housing.

FIGS. 28-30 are illustrations of exemplary embodiments of baffleassemblies.

FIG. 31 is a schematic illustration of an exemplary embodiment of asystem for heating and vaporizing fluidic materials.

FIG. 32 is a schematic illustration of an exemplary embodiment of asystem for heating and vaporizing fluidic materials.

FIG. 33 is a fragmentary cross sectional view of the vessel, heaterelements and coalescing filter material of the system of FIG. 32.

FIG. 34 is an illustration of an exemplary experimental embodiment ofthe system of FIG. 31.

FIG. 35 is an illustration of an exemplary experimental embodiment ofthe system of FIG. 31.

FIG. 36 is an illustration of an exemplary experimental embodiment ofthe system of FIG. 31.

FIG. 37 is an illustration of an exemplary experimental embodiment ofthe system of FIG. 31.

FIG. 38 is a fragmentary schematic illustration of an exemplaryembodiment of a system for heating and vaporizing fluidic materials.

FIG. 39 is a schematic illustration of an exemplary embodiment of amulti-stage distillation column assembly that includes one or more ofthe heaters 3100 and/or 3200 in series.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, fuel gas conditioning system 11 includes a pressurevessel 13 having an interior chamber 12. Pressure vessel 13 ispreferably cylindrical and has two closed ends 14, 16. The length ofpressure vessel 13 considerably greater than its diameter. In thisexample, the longitudinal axis of pressure vessel 13 is horizontal.

A pre-heater unit 15 is mounted in pressure vessel 13 with its axisparallel and offset from the longitudinal axis of pressure vessel 13.Pre-heater unit 15 has a length somewhat greater than the length ofpressure vessel 13 in this example, with its ends protruding past ends14, 16 of pressure vessel 13. Pre-heater unit 15 has an outer tubularhousing 17 and a concentric inner tubular housing 19, defining anannulus 21 between housings 17, 19. A plurality of electrical heaterelements 23 extend longitudinally within inner housing 19.

Heater elements 23 are conventional elements, each comprising a metaltube containing an electrical resistance wire electrically insulatedfrom the tube. In this embodiment, heater elements 23 are U-shaped, eachhaving its terminal ends mounted within a connector housing 25 locatedexterior of end 14 of pressure vessel 13. The bent portions of heaterelements 23 are located near the opposite end of pre-heater unit 15. Apower controller 27 supplies power via wires 29 to electrical heaterelements 23. Power controller 27 varies the power in response totemperature sensed by a temperature sensor 31 that is located withinchamber 12 in pressure vessel 13.

Pre-heater unit 15 has an inlet 33 that leads to the interior of innerhousing 19 of pre-heater unit 15 in the portion of pre-heater unit 15exterior of pressure vessel end 14. In the embodiment of FIG. 1, anexternal conduit loop 35 is located on the opposite end of pre-heaterunit 15, exterior of pressure vessel end 16. External loop 35 leads fromthe interior of inner housing 19 to annulus 21. A variable expansionvalve 37 is located in external loop 35 for reducing the pressure of thegas flowing through external loop 35, which also results in cooling ofthe gas. Expansion valve 37 varies the amount of pressure drop inresponse to a pressure sensor 39 located within pressure vessel chamber12.

Annulus 21 has an outlet 41 located within pressure vessel chamber 12near end 14. A mist or coalescing filter 43 is located within pressurevessel chamber 12 approximately halfway between ends 14, 16 of pressurevessel 13. Coalescing filter 43 collects liquid mist from the gasflowing from annulus outlet 41 towards the pressure vessel end 16.

A super-heater 45 is mounted in pressure vessel chamber 12. Super-heater45 has an elongated tubular housing 47 that has an axis parallel withthe axis of pre-heater unit 15 and offset from the axis of pressurevessel 13. Super-heater 45 is located above pre-heater unit 15 in thisexample and has a length that is less than the length of pre-heater unit15. Super-heater 45 has an inlet 49 in housing 47, inlet 49 being withinpressure vessel chamber 12 and closer to pressure vessel end 16 than end14. Super-heater 45 has a plurality of electrical resistance heaterelements 51 located within housing 47.

Electrical resistance heater elements 51 may be of the same type aselectrical resistance heater elements 23 of pre-heater unit 15.Preferably, each is U-shaped with both of its terminal ends mountedwithin an a connector housing 53, which is external of end 14 ofpressure vessel 13. A power controller 55 supplies power to electricalresistance heater elements 51. Power controller 55 controls the power inresponse to temperature sensed by a temperature sensor 57 located withinan outlet 59 of super-heater 45. In this embodiment, outlet 59 leadsfrom a portion of super-heater housing 47 that is external of pressurevessel 13.

Pressure vessel 13 has at least one drain 61 for draining liquid thatcondenses within chamber 13 upstream of filter 43 as a result of thepressure drop. A second drain 63 drains liquid that separates from thegas as a result of flowing through filter 43. Drains 61, 63 are locatedon opposite sides of filter 43 and lead downward from a lower point onthe sidewall of pressure vessel 13. Each drain 61, 63 leads to aseparate sump 65, 66. In this example, sumps 65, 66 are compartments ofa single tubular pressure vessel and separated from each other by asealed plate 67. Outlets 69, 71 lead from the bottom of sumps 65, 66 toliquid control valves 73, 75. Each liquid control valve 73, 75 has alevel controller 77, 79, respectively. Level controllers 77, 79 areconventional devices to open valves 73, 75 when the levels of liquidwithin sumps 65, 66 reach a selected amount, so as to discharge theliquid from sumps 65, 66. Other automatic drain arrangements arefeasible.

Pressure vessel 13 has a pressure relief valve 81 in communication withits chamber 12. Pressure relief valve 81 is a conventional device torelieve pressure in the event that it reaches an excessive amount.Preferably, pressure vessel 13 has an access port 82 with a removablecap. Access port 82 is located in its sidewall in this embodiment.Access port 82 is of a size selected to allow a worker to enter chamber12 for maintenance, particularly for removing and installing coalescingfilter 43, which must be done periodically.

Referring to FIG. 2, coalescing filter 43 comprises an assembly ofcompressible pieces or segments that define an outer diameter thatsealingly engages the inner diameter of pressure vessel 13. The multiplepieces of coalescing filter 43 are sized so that each will pass throughaccess port 82 (FIG. 1). These pieces include in this example a pair ofcentral segments 83, 85 having inner edges 87 and outer edges 89 thatare straight and parallel with each other. Inner edges 87 sealingly abuteach other. Each inner edge 87 has a semi-cylindrical recess 91 forengaging super-heater 45. Each inner edge 87 has a semi-cylindricalrecess 93 for fitting around pre-heater unit 15. Each central segment83, 85 has outer diameter portions 95 on opposite ends that arepartially cylindrical and sealingly engage the inner diameter ofpressure vessel 13.

Coalescing filter 43 also has two side segments 97, 99 in thisembodiment. Each side segment 97, 99 has a straight inner edge 101 thatabuts one of the outer edges 89 of one of the central segments 83, 85.Each side segment 97 has an outer diameter portion 103 that sealsagainst the inner diameter of pressure vessel 13. Segments 83, 85, 97and 99 are compressible so as to exert retentive forces against eachother and against pressure vessel 13 to hold them in place. Retainers(not shown) may also be employed to hold the segments of coalescingfilter 43 in position.

Fuel gas conditioning system 11 serves to condition fuel gas for gasturbines. Gas turbines, particularly low pollution types, require a dryfeed gas that has a selected amount of superheat, such as 50 degreesabove its dew point curve. The term “superheat” is a conventionalindustry term to refer to a range where the pressure and temperature ofthe fuel gas are above a range where condensation can occur. Referringto FIG. 1, feed gas enters inlet 49 at a pressure that may be, forexample, 1,000 to 1,300 psig and at a temperature from 60-80° F.° F. Thefeed gas flows through inner housing 19 of pre-heater unit 15, whichincreases the temperature of the feed gas a selected amount over thetemperature of the incoming gas. For example, the temperature may beapproximately 100-120° F.° F. as it exits inner housing 19, and thepressure would be approximately the same as at inlet 49.

This preheated gas then flows through expansion valve 37, causing apressure drop to a selected level below the dew point curve, asmonitored by pressure sensor 39. For example, if the intake pressure is1,000 to 1,300 psig, the pressure may drop to approximately 450-500psig. The temperature will also drop to perhaps 60-80° F., and at thistemperature and pressure, the gas will be below its dew point curve. Thelower pressure cooler gas flows back through annulus 21 in pre-heaterunit 15, which adds additional heat. At annulus outlet 41, the pressuremay still be around 450-550 psig and the temperature may be 70-100° F.,but still below the dew point. Controller 27 controls the power toheater elements 23 to maintain a desired temperature at outlet 41 asmonitored by sensor 31.

Because the drop in pressure at expansion valve 37 caused the gas to bebelow its dew point, some of the liquids contained within the gas willcondense in chamber 14 upstream of filter 43. Also, liquids will beseparated from the gas by coalescing filter 43 as the gas flows throughcoalescing filter 43. The liquids collect on the bottom of pressurevessel 13 and flow through outlets 61, 63 into sumps 65, 66 and outthrough valves 73, 75.

After passing through filter 43, the gas flows toward pressure vesselend 16 and enters inlet 49 of super-heater 45. Electrical resistanceheater elements 51 add heat to the dry gas in an amount that will placethe temperature of the gas well above its dew point curve, such as by 50degrees. The gas, now in a superheated condition, flows out outlet 59 atfor example 110-130° F.° F. and 450-550 psig. The gas from outlet 59flows into a conventional gas turbine (not shown).

FIG. 3 shows a portion of an alternate embodiment wherein pressurevessel 105 contains an expansion valve 107 within its interior. In thefirst embodiment, expansion valve 37 is located on the exterior ofpressure vessel 13. In FIG. 3, pre-heater inner housing 109 and outerhousing 11 have one end within pressure vessel 105 instead of on theexterior as in the first embodiment. Heater elements 113 are containedwithin inner housing 109 as in the first embodiment. A valve actuator115 controls the orifice of expansion valve 107. Valve actuator 115varies the pressure drop in response to pressure sensed by a pressuresensor 117 located within the interior of pressure vessel 105. Thesecond embodiment operates in the same manner as the first embodiment.

The gas conditioner is compact as the components are principallycontained within a single pressure vessel. This arrangement reduces theamount of space required and the external flowlines connecting thevarious components.

Referring now to FIGS. 4, 5 and 6, an exemplary embodiment of a fuel gasconditioning system 200 includes a preheater assembly 202 that includesan outer tubular housing 204 and an inner tubular housing 206 thatdefines a longitudinal passage 206 a that is positioned and supportedwithin the outer tubular housing. An annulus 208 is thereby definedbetween the outer and inner tubular housings, 204 and 206. Heatingelements, 210 a and 210 b, are positioned and supported within thepassage 206 a of the inner tubular housing 206. In an exemplaryembodiment, the heating element 210 a extends through and is positionedwithin an upper portion of the inner tubular housing 206 and the heatingelement 210 b extends through and is positioned within a lower portionof the inner tubular housing 206. In an exemplary embodimentlongitudinally spaced apart baffles, 214 and 216, are received withinand are coupled to the inner tubular housing 206.

The baffle 214 defines a longitudinal passage 214 a for receiving aportion of the heating element 210 a and the baffle 216 defines alongitudinal passage 216 a for receiving a portion of the heatingelement 210 b. In an exemplary embodiment, the baffle 214 includes aperipheral arcuate portion that engages and mates with an upper portionof the interior surface of the inner tubular housing 206 and the baffle216 includes a peripheral arcuate portion that engages and mates with anlower portion of the interior surface of the inner tubular housing. Inthis manner, an annular axial flow passage 218 is defined between theheating elements 210 a and the baffle 214 and an annular axial flowpassage 220 is defined between the heating element 210 and the baffle216. Furthermore, in this manner, a lower axial flow passage 222 isdefined between the lower periphery of the baffle 214 and the interiorsurface of the lower portion of the inner tubular housing 206 and anupper axial flow passage 224 is defined between the lower periphery ofthe baffle 216 and the interior surface of the upper portion of theinner tubular housing 206. In this manner, the flow of fluidic materialsin an axial direction through the inner tubular housing 206 may flowthrough the annular passages, 218 and 220, and in a serpentine path byvirtue of the apart axial flow passages 222 and 224.

In an exemplary embodiment, the inside diameters of the longitudinalpassages, 214 a and 216 a, of the spaced apart baffles, 214 and 216, areabout 1/16^(th) to ⅛^(th) inch greater than the outside diameters of theheating elements, 210 a and 210 b, that pass therethrough.

In an exemplary embodiment, the outer tubular housing 204 may befabricated from, for example, a lower carbon steel tube having a wallthickness of about 0.280 inches and the inner tubular housing 206 may befabricated from, for example, an H grade stainless steel having a wallthickness of about 0.134 inches. In an exemplary embodiment, thelongitudinal spacing of the baffles, 214 and 216, may, for example, beabout equal to the internal diameter of the inner tubular housing 206.In an exemplary embodiment, the heating elements 210 a and 210 b, may,for example, be conventional electrical operating heating elements suchas, for example, heating elements commercially available from GaumerProcess in Houston, Tex.

A source 222 of an inlet stream of fluidic material is operably coupledto one end of the annulus 208 by a conduit 224 for conveying the inletstream of fluidic materials into the annulus and a conduit 226 isoperably coupled to another end of the annulus for conveying fluidicmaterials from the other end of the annulus into an end of the passage206 a. A conduit 228 is operably coupled to another end of the passage206 a for conveying fluidic materials from the other end of the passageinto an outlet stream 230. In this manner, fluidic materials flowthrough the preheater assembly 202 by entering one end of the annulus208, traveling through to the other end of the annulus, exiting theother end of the annulus through the conduit 226, entering one end ofthe passage 206 a, passing through the passage, including passingthrough the annular axial passages, 218 and 220, and the axial passages,222 and 224, and finally exiting the other end of the passage 206 a intothe passage 228 into an outlet stream 230. Thus, fluidic materials flowin one axial direction within the annulus 208 and in an opposite axialdirection within the passage 206 a.

In an exemplary embodiment, the source 222 of an inlet stream of fluidicmaterial may, for example, include gaseous, liquid, ambient air, and/ornatural gas materials and the outlet 230 may, for example, be used toprovide a fuel source for a gas turbine.

In an exemplary embodiment, a controller 232 is operably coupled to theheating elements, 210 a and 210 b, for controlling the operation of theheating elements. In an exemplary embodiment, the controller 232 isfurther operably coupled to thermocouples, 234, 236 and 238, that inturn are operably coupled to the fluidic materials within the conduits,224, 226 and 228. In this manner, the controller 232 may monitor theoperating temperature of the fluidic materials within the conduits, 224,226 and 228. In an exemplary embodiment, the controller 232 is alsooperably coupled to a flow control valve 238 for controlling the flow offluidic materials through the conduit 226.

In an exemplary embodiment, during operation, fluidic materials from thesource 222 are conveyed into one end of the annulus 208 by the conduit224. Within the conduit 208, the fluidic materials are preheated by heattransmitted into the annulus through the walls of the inner tubularhousing 206. Thus, in an exemplary embodiment, the operating temperatureof the fluidic materials at the end of the annulus 208 are increased asthey pass from the end of the annulus to the other end of the annulus.The fluidic materials then exit the other end of the annulus 208 and areconveyed to the end of the passage 206 a by the conduit 226. Within thepassage 206 a, the fluidic materials are heated further by theirinteraction with the heating elements, 210 a and 210 b. The heating ofthe fluidic materials within the passage 206 a by the heating elements,210 a and 210 b, is significantly enhanced by forcing the fluidicmaterials to pass through the annular passages, 218 and 220, and theserpentine flow in the axial direction due to the baffles, 214 and 216.As a result, the operating temperature of the fluidic materials at theend of the passage 206 a are significantly increased as they passthrough the passage to the other end of the passage. The fluidicmaterials then exit the other end of the passage 206 a and are conveyedto the outlet stream 230 by the conduit 228.

In an exemplary embodiment, the system 200 includes a plurality ofbaffles 214 which are interleaved with a plurality of baffles 216. In anexemplary embodiment, the system 200 includes a plurality of heatingelements, 210 a and 210 b.

In a first exemplary experimental embodiment, the system 200 of FIGS. 4,5 and 6 was operated and yielded the following results:

Elements of the system 200 Parameter Value The outer tubular housing 2046 inch, schedule 40, carbon steel pipe The inner tubular housing 206 5inch, schedule 10, 304H stainless steel pipe Number, spacing and outsidediameter of 9, 5 inches, and 0.475 inches heating elements 210 Number ofbaffles, 214 and 216 10 baffles 214 interleaved with 10 baffles 216Temperature and mass flow rate of inlet 70° F. and 293 lbs/hour stream218 Temperature of outlet stream 226 1200° F. Heat transfer coefficientof the system 200 25.31 btu/hr*ft²*° F.

In a second exemplary experimental embodiment, the system 200 of FIGS.4, 5 and 6 was operated, without the baffles, 214 and 216, and yieldedthe following results:

Elements of the system 200 Parameter Value The outer tubular housing 2046 inch, schedule 40, carbon steel pipe The inner tubular housing 206 5inch, schedule 10, 304H stainless steel pipe Number, spacing and outsidediameter of 9, 1.5 inches, and 0.475 inches heating elements 210 Numberof baffles, 214 and 216 N/A Temperature and mass flow rate of inlet 70°F. and 293 lbs/hour stream 218 Temperature of outlet stream 226 1200° F.Heat transfer coefficient of the system 200 4 btu/hr*ft²*° F.

In a third exemplary experimental embodiment, the system 200 of FIGS. 4,5 and 6 was operated and yielded the following results:

Elements of the system 200 Parameter Value The outer tubular housing 20414 inch, standard carbon steel pipe The inner tubular housing 206 12inch, schedule 10, 304H stainless steel pipe Number, spacing and outsidediameter of 48, 1.5 inches, and 0.475 inches heating elements 210 Numberof baffles, 214 and 216 5 baffles 214 interleaved with 5 baffles 216Temperature and mass flow rate of inlet 80° F. and 1880 lbs/hour stream218 Temperature of outlet stream 226 1000° F. Heat transfer coefficientof the system 200 72.07 btu/hr*ft²*° F.

In a fourth exemplary experimental embodiment, the system 200 of FIGS.4, 5 and 6 was operated, without the baffles, 214 and 216, and yieldedthe following results:

Elements of the system 200 Parameter Value The outer tubular housing 20414 inch, standard carbon steel pipe The inner tubular housing 206 12inch, schedule 10, 304H stainless steel pipe Number, spacing and outsidediameter of 48, 1.5 inches, and 0.475 inches heating elements 210 Numberof baffles, 214 and 216 N/A Temperature and mass flow rate of inlet 80°F. and 1880 lbs/hour stream 218 Temperature of outlet stream 226 1000°F. Heat transfer coefficient of the system 200 12.2 btu/hr*ft²*° F.

In a fifth exemplary experimental embodiment, the system 200 of FIGS. 4,5 and 6 was operated and yielded the following results:

Elements of the system 200 Parameter Value The outer tubular housing 20414 inch, standard carbon steel pipe The inner tubular housing 206 12inch, schedule 10, 304H stainless steel pipe Number, spacing and outsidediameter of 36, 1.5 inches, and 0.475 inches heating elements 210 Numberof baffles, 214 and 216. 13 baffles 214 interleaved with 13 baffles 216Temperature and mass flow rate of inlet 80° F. and 1135 lbs/hour stream218 Temperature of outlet stream 226 800° F. Heat transfer coefficientof the system 200 57.8 btu/hr*ft²*° F.

In a sixth exemplary experimental embodiment, the system 200 of FIGS. 4,5 and 6 was operated, without the baffles, 214 and 216, and yielded thefollowing results:

Elements of system 200 Parameter Value The outer tubular housing 204 14inch, standard carbon steel pipe The inner tubular housing 206 10 inch,schedule 10, 304H stainless steel pipe Number, spacing and outsidediameter of 36, 1.5 inches, and 0.475 inches heating elements 210 Numberof baffles, 214 and 216 N/A Temperature and mass flow rate of inlet 80°F. and 1135 lbs/hour stream 218 Temperature of outlet stream 226 800° F.Heat transfer coefficient of the system 200 9.8 btu/hr*ft²*° F.

In a seventh exemplary experimental embodiment, the system 200 of FIGS.4, 5 and 6 was operated and yielded the following results:

Elements of the system 200 Parameter Value The outer tubular housing 20410 inch, schedule 40, carbon steel pipe The inner tubular housing 206 8inch, schedule 10, 304H stainless steel pipe Number, spacing and outsidediameter of 24, 1.5 inches, and 0.475 inches heating elements 210 Numberof baffles, 214 and 216 13 baffles 214 interleaved with 13 baffles 216Temperature and mass flow rate of inlet 348° F. and 1628 lbs/hour stream218 Temperature of outlet stream 226 800° F. Heat transfer coefficientof the system 200 53.23 btu/hr*ft²*° F.

In a eighth exemplary experimental embodiment, the system 200 of FIGS.4, 5 and 6 was operated, without the baffles, 214 and 216, and yieldedthe following results:

Elements of the system 200 Parameter Value The outer tubular housing 20410 inch, schedule 40, carbon steel pipe The inner tubular housing 206 8inch, schedule 10, 304H stainless steel pipe Number, spacing and outsidediameter of 24, 1.5 inches, and 0.475 inches heating elements 210 Numberof baffles, 214 and 216 N/A Temperature and mass flow rate of inlet 348°F. and 1628 lbs/hour stream 218 Temperature of outlet stream 226 800° F.Heat transfer coefficient of the system 200 9.2 btu/hr*ft²*° F.

The exemplary test results of the system 200 that demonstrated anincreased heat transfer for the system 200 with the baffles, 214 and216, versus the system without the baffles were unexpected.

In an exemplary embodiment, one or more of the baffles, 216 and 218,within the system 200 may be omitted.

In an exemplary embodiment, during the operation of the system 200, theheat generated by the heating elements 210 is transmitted by acombination of radiation, conduction and convection to the interiorsurface of the inner tubular housing 206. As a result, the operatingtemperature of the inner tubular housing 206 is increased and thefluidic material that flows within the annular passage 208 may bepre-heated by heat transmitted from the exterior surface of the innertubular housing 206 to the annular passage by a combination ofradiation, conduction and convection. Furthermore, as a result, thematerial composition of the outer tubular housing 204 that is requiredfor typical operating conditions does not have to be as tolerant of heatand temperature as the inner tubular housing 206. For example, fortypical operating conditions of the system 200, the outer tubularhousing 204 may be fabricated from a carbon steel pipe while the innertubular housing 206 may be fabricated from a high temperature stainlesssteel pipe.

In an exemplary embodiment, the counter flow of the fluidic materialswithin the system 200, through the inner passage 206 a in a first axialdirection, and the outer annular passage 208 in a second opposite axialdirection, enhances heat transfer to the fluidic material that passthrough the system and thereby decreases the response time within thesystem to changes in operating conditions such as, for example, stepchanges in one or more of the flow rate, the operating temperature(s),and the fluid composition.

In an exemplary embodiment, the use of outer and inner tubular housings,204 and 206, in which the inner tubular housing houses the heatingelements 210 and contains the radiant energy generated by the heatingelements, permits the composition of the outer tubular housing to beless tolerant of high temperature operating conditions and therebycomposed of a typically less expensive and lighter weight material.

In an exemplary embodiment, the use of outer and inner tubular housings,204 and 206, in which the inner tubular housing houses the heatingelements 210 and contains the radiant energy generated by the heatingelements, and the counter flow and forced convection of the fluidicmaterials within the system 200, through the inner passage 206 a in afirst direction, and the outer annular passage 208 in a second oppositedirection, enhances heat transfer.

In an exemplary embodiment, one or more aspects of the system of FIGS.1, 2 and 3 may be combined in whole, or in part, with one or moreaspects of the systems of FIGS. 4, 5 and 6.

In an exemplary experimental embodiment, as illustrated in FIG. 7,operation of the system 200 of FIG. 4 provided a serpentine flow patternwithin the inner tubular housing 206 due to the presence of the baffles,214 and 216.

Referring now to FIG. 8, an exemplary embodiment of a baffle assembly300 includes a first baffle element 302, a second baffle element 304, athird baffle element 306, a fourth baffle element 308, and a hinge 310that is coupled to each of the first, second, third and fourth baffleelements. The first, second, third, and further baffle elements, 302,304, 306 and 308, each define one or more passageways, 302 a, 304 a, 306a and 308 a, respectively, and the hinge 310 at least partially definesone or more passageways 310 a.

The first baffle element 302 includes an outer peripheral portion 302 bhaving an arcuate shape, an inner peripheral portion 302 c that ispivotally coupled to one side of the hinge 310 having a linear shape,and a side peripheral portion 302 d having a linear shape. The secondbaffle element 304 includes an outer peripheral portion 304 b having anarcuate shape, an inner peripheral portion 304 c that is pivotallycoupled to another side of the hinge 310 having a linear shape, and aside peripheral portion 304 d having a linear shape. The third baffleelement 306 includes an outer peripheral portion 306 b having an arcuateshape, an inner peripheral portion 306 c that is pivotally coupled tothe one side of the hinge 310 having a linear shape, and a sideperipheral portion 306 d having a linear shape. The fourth baffleelement 308 includes an outer peripheral portion 308 b having an arcuateshape, an inner peripheral portion 308 c that is pivotally coupled tothe other side of the hinge 310 having a linear shape, and a sideperipheral portion 308 d having a linear shape. In an exemplaryembodiment, the outer peripheral surfaces of the first, second, third,and fourth baffle elements, 302, 304, 306 and 308, respectively, and thehinge 310, together define a circular shape.

In an exemplary embodiment, the radius of curvatures of the arcuateshaped outer peripheral portions 302 b, 304 b, 306 b and 308 b, of thefirst, second, third and fourth baffle elements, 302, 304, 306 and 308,respectively, are substantially constant and equal to one another. In analternative embodiment, one or more of the radius of curvatures of thearcuate shaped outer peripheral portions 302 b, 304 b, 306 b and 308 b,of the first, second, third and fourth baffle elements, 302, 304, 306and 308, respectively, may be variable and/or not equal to one or moreof the other radius of curvatures.

In an exemplary embodiment, because of the pivotal connections of thefirst, second, third and fourth baffle elements, 302, 304, 306 and 308,respectively, to the hinge 310, the first, second, third and fourthbaffle elements may each be independently positioned in correspondingplane which may, for example, be different from one another.

In an exemplary embodiment, the angular spacing between the first,second, third and fourth baffle elements, 302, 304, 306 and 308,respectively, ranges from about 15 to 75 degrees.

Referring now to FIG. 9, an exemplary embodiment of a baffle assembly400 includes a first baffle element 402, a second baffle element 404,and a hinge 406 that is coupled to each of the first and second baffleelements. The first and second baffle elements, 402 and 404, each defineone or more passageways, 402 a and 404 a, respectively.

The first baffle element 402 includes an outer peripheral portion 402 bhaving an arcuate shape, an inner peripheral portion 402 c having alinear shape, and a side peripheral portion 402 d having a linear shape.The second baffle element 404 includes an outer peripheral portion 404 bhaving an arcuate shape, an inner peripheral portion 404 c having alinear shape, and a side peripheral portion 404 d having a linear shape.

In an exemplary embodiment, the outer peripheral surfaces of the firstand second fourth baffle elements, 402 and 404, respectively, togetherdefine a semi-circular shape.

In an exemplary embodiment, the radius of curvatures of the arcuateshaped outer peripheral portions 402 b and 404 b of the first and secondbaffle elements, 402 and 404, respectively, are substantially constantand equal to one another. In an alternative embodiment, one or more ofthe radius of curvatures of the arcuate shaped outer peripheral portions402 b and 404 b of the first and second baffle elements, 402 and 404,respectively, may be variable and/or not equal to one or more of theother radius of curvatures.

In an exemplary embodiment, because of the pivotal connections of thefirst and second baffle elements, 402 and 404, respectively, to thehinge 406, the first and second baffle elements may each beindependently pivoted about an axis of rotation 408 to correspondingplanes which may, for example, be different from one another.

In an exemplary embodiment, the angular spacing between the first andsecond baffle elements, 402 and 404, respectively, ranges from about 15to 75 degrees.

Referring now to FIGS. 10-12, an exemplary embodiment of a baffleassembly 500 includes the baffle assembly 300 and the baffle assembly400 positioned proximate one another. In an exemplary embodiment, in thebaffle assembly 500, the first and second baffle elements, 302 and 304,respectively, of the baffle assembly 300 are positioned in a commonplane, and the third and fourth baffle elements, 306 and 308,respectively, of the baffle assembly 300 are positioned in anothercommon plane. In an exemplary embodiment, in the baffle assembly 500,the first and second baffle elements, 402 and 404, respectively, of thebaffle assembly 400 are positioned in different planes. In an exemplaryembodiment, in the baffle assembly 500, the common plane of the firstand second baffle elements, 302 and 304, respectively, of the baffleassembly 300, the common plane of the third and fourth baffle elements,306 and 308, respectively, of the baffle assembly 300, the plane of thefirst baffle element 402 of the baffle assembly 400, and the plane ofthe second baffle element 404 of the baffle assembly 400 are alldifferent from one another. In an exemplary embodiment, in the baffleassembly 500, the longitudinal axis of the hinge 310 of the baffleassembly 300 is positioned in a different orientation from the axis ofrotation 408 of the baffle assembly 400.

Referring now to FIGS. 13-15, an assembly 600 is shown that includes atubular housing 602 that defines a longitudinal passageway 602 a, aradial passage 602 b and a radial passage 602 c and includes an open end602 d and closed end 602 e. A plurality of the baffle assemblies 500a-500 g, all substantially identical to the baffle assembly 500, arepositioned proximate to one another within the passageway 602 a of thetubular housing 602 extend from a location proximate the radial passage602 b to a location proximate the radial passage 602 c. In an exemplaryembodiment, at least a portion of one or more of the arcuate outerperipheral portions, 302 b, 304 b, 306 b, 308 b, 402 b and 404 b, of thebaffle assemblies, 300 and 400, mate with the interior surface of thetubular housing 602.

Referring now to FIGS. 16-19, as assembly 700 is shown in which aplurality of heating elements 702 are positioned within the tubularhousing 602 of the assembly 600, with each of the heating elementspassing through corresponding passageways, 302 a, 304 a, 306 a, 308 a,402 a and 404 a, of the baffle assemblies 500. In an exemplaryembodiment, the heating elements 702 extend in a longitudinal directionwithin the housing 602 and are parallel to one another within thehousing. In an exemplary embodiment, the heating elements 702 extendfrom the open end 602 d of the housing to a positioned proximate theradial passage 602 c. In an exemplary embodiment, the outside diameterof the heating elements 702 are less than the inside diameters of thecorresponding passageways, 302 a, 304 a, 306 a, 308 a, 402 a and 404 a,in the baffle assemblies 500. In an exemplary embodiment, the design andoperation of the heating elements 702 is substantially identical to theheating elements 210.

Referring now to FIG. 20, an exemplary embodiment of a fuel gasconditioning system 800 includes a preheater assembly 802 in which theassembly 700, including the baffle assemblies 500, tubular housing 602,and heating elements 702, as described and illustrated above withreference to FIGS. 16-19, is positioned and supported within an outertubular housing 804. An annulus 806 is thereby defined between the outerand inner tubular housings, 804 and 602.

A source 808 of an inlet stream of fluidic material is operably coupledto one end of the annulus 806 by a conduit 810 for conveying the inletstream of fluidic materials into the annulus and a conduit 812 isoperably coupled to another end of the annulus for conveying fluidicmaterials from the other end of the annulus into an end of the passage602 a of the housing 602. In an exemplary embodiment, the conduit 812may, for example, be either the radial passage 602 b or 602 c of thehousing 602.

A conduit 814 is operably coupled to another end of the passage 602 a ofthe housing 602 for conveying fluidic materials from the other end ofthe passage into an outlet stream 816. In an exemplary embodiment, theconduit 814 may, for example, be either the radial passage 602 b or 602c of the housing 602. In this manner, fluidic materials flow through thepreheater assembly 802 by entering one end of the annulus 806, travelingthrough to the other end of the annulus, exiting the other end of theannulus through the conduit 812, entering one end of the passage 602 aof the housing 602, passing through the passage, and finally exiting theother end of the passage 602 a of the housing 602 into the passage 814into an outlet stream 816. Thus, fluidic materials flow in one axialdirection within the annulus 806 and in an opposite axial directionwithin the passage 602 a of the housing 602.

In an exemplary embodiment, the source 808 of an inlet stream of fluidicmaterial may, for example, include gaseous, liquid, ambient air, and/ornatural gas materials and the outlet 816 may, for example, be used toprovide a fuel source for a gas turbine.

In an exemplary embodiment, a controller 818 is operably coupled to theheating element 702 for controlling the operation of the heatingelements. In an exemplary embodiment, the controller 818 is furtheroperably coupled to thermocouples, 820, 822 and 824, that in turn areoperably coupled to the fluidic materials within the conduits, 810, 812and 814. In this manner, the controller 818 may monitor the operatingtemperature of the fluidic materials within the conduits, 820, 822 and824. In an exemplary embodiment, the controller 818 is also operablycoupled to a flow control valve 826 for controlling the flow of fluidicmaterials through the conduit 812.

In an exemplary embodiment, during operation of the fuel gasconditioning system 800, fluidic materials from the source 808 areconveyed into one end of the annulus 806 by the conduit 810. Within theannulus 806, the fluidic materials are preheated by heat transmittedinto the annulus through the walls of the inner tubular housing 602.Thus, in an exemplary embodiment, the operating temperature of thefluidic materials at the end of the annulus 806 are increased as theypass from the end of the annulus to the other end of the annulus. Thefluidic materials then exit the other end of the annulus 806 and areconveyed to the end of the passage 602 a of the tubular housing 602 bythe conduit 812. Within the passage 602 a of the housing 602, thefluidic materials are heated further by their interaction with theheating elements 702. The heating of the fluidic materials within thepassage 602 a of the housing 602 by the heating elements 702 issignificantly enhanced by forcing the fluidic materials to pass throughthe flow passages defined by the baffle assemblies 500. As a result, theoperating temperature of the fluidic materials at the end of the passage602 a of the housing 602 are significantly increased as they passthrough the passage to the other end of the passage. The fluidicmaterials then exit the other end of the passage 602 a and are conveyedto the outlet stream 816 by the conduit 814.

In an exemplary embodiment, during operation of the during operation ofthe fuel gas conditioning system 800, the flow passages defined by thebaffle assemblies 500 constantly shear the fluidic materials therebycausing the fluidic materials to pass over the heating elements 702 atan angle as opposed to having the fluidic materials running along thelength of the heating elements thereby enhancing the heating transferfrom the heating elements to the fluidic material. In an exemplaryembodiment, during operation of the during operation of the fuel gasconditioning system 800, the flow passages defined by the baffleassemblies 500 constantly mix the fluidic materials around the heatingelements 702 thereby enhancing the heating transfer from the heatingelements to the fluidic material.

Referring to FIGS. 21-23, in an exemplary experimental embodiment of thefuel gas conditioning system 800, the operating temperatures of thefluidic materials within the tubular housing 602, the operatingtemperatures of the heating elements 702 within the tubular housing, andthe operating pressures of the fluidic materials within the tubularhousing were generated in a computer generated simulation of theoperation of the fuel gas conditioning system.

In several exemplary experimental embodiments, the systems 11, 200 and800 were operated, using predictive computer models of the systems withdiffering sets of operating parameters, and the results compared, assummarized below:

Heat Transfer Coefficient (Btu/(hr*ft²*° F.)) System 11 System 200System 800 Operating Parameter 8.87 28.8 12.3 Set 1 Operating Parameter4.42 31.4 14 Set 2 Operating Parameter 15.74 72 33 Set 3

Operating Temperature of the Heating Elements (° F.) System 11 System200 System 800 Operating Parameter 1207 869 1090 Set 1 OperatingParameter 1654 942 1147 Set 2 Operating Parameter 987 638 757 Set 3

The exemplary tabular experimental results for the systems 11, 200 and800 presented above were unexpected results.

As demonstrated by the exemplary experimental results above, the heattransfer coefficient was highest for the system 200 and lowest for thesystem 11 when the fluidic materials were being heated by the heatingelements, 210 and 702, respectively. However, the range of operatingtemperatures within the fluidic materials within the system 800 was lessthan that for the system 200 when the fluidic materials were beingheated by the heating elements, 210 and 702, respectively. As a result,the variation in the operating temperatures of the fluidic materialswithin the system 800 while being heated by the heating elements 702 wasless than the variation in the operating temperatures of the fluidicmaterials within the system 200 while being heated by the heatingelements 210. As a result, in the system 800, the heating elements 702may be operated at a higher operating temperature since stresses thatmight other damage the heating elements, such as wide temperaturevariations in the fluidic materials being heated thereby, are reducedversus the system 200.

The exemplary experimental results summarized above further demonstratedthat fluidic materials within the system 11 tend to flow in alongitudinal direction along the exterior surfaces of the heatingelements, 23 and 51.

The exemplary experimental results summarized above further demonstratedthat fluidic materials within the system 200 generally tend to flow in adirection approximately transverse to the exterior surfaces of theheating elements 210. However, as a result, the heat transfer from theheating elements 210 to the fluidic materials may not be uniform whichcan result in regions within the fluidic materials having differentoperating temperatures.

The exemplary experimental results summarized above further demonstratedthat fluidic materials within the system 800 uniformly tend to flow in adirection approximately transverse to the exterior surfaces of theheating elements 702. In the exemplary experimental embodiment of thesystem 800, the fluid materials were deflected by the baffle assemblies500 at angles ranging from 15 to 75 degrees. As a result, the heattransfer from the heating elements 702 to the fluidic materials istypically uniform which results in uniform operating temperatures withinthe fluidic materials. As a result, the operating temperatures of theheating elements 702 may be significantly higher and the operation ofthe heating elements is more reliable and failure rates are reduced.

In an exemplary experimental embodiment, as illustrated in FIG. 24, thesystem 800, using the operating parameter set 1, as also summarizedabove, the operating temperature of the wall of the tubular housing 602ranged from about 713° F. near the inlet to about 917° F. near theoutlet and the heat generation of the heating elements 702 within thetubular housing was about 212,990 Btu/hr. Furthermore, the operatingpressure of the fluidic materials near the inlet of the tubular housing602 was about 56.9 lbf/in² and the mass flow rate of the fluidicmaterials near the outlet of the tubular housing was about 0.897lb/second.

In an exemplary experimental embodiment, as illustrated in FIG. 25, thesystem 800, using the operating parameter set 1, as also summarizedabove, the operating temperature of the heating elements 702 within thetubular housing 602 ranged from about 713° F. near the inlet to about1090° F. near the outlet. Furthermore, as demonstrated in FIG. 25, inthe system 800, the operating temperature of the heating elements 702increase in a substantial even fashion in a direction from the inlet tothe outlet of the tubular housing 602.

In an exemplary experimental embodiment, as illustrated in FIG. 26, thesystem 800, using the operating parameter set 1, as also summarizedabove, the operating temperature of the fluidic materials within thetubular housing 602 ranged from about 710° F. near the inlet to about854° F. near the outlet.

In an exemplary experimental embodiment, as illustrated in FIG. 27, thesystem 800, using the operating parameter set 1, as also summarizedabove, the fluidic materials within the tubular housing 602 aredeflected by the baffle assemblies 500 to flow in directionssubstantially transverse to the heating elements 702.

Referring now to FIGS. 28-30, several exemplary embodiments of tubularhousings that include baffle assemblies 900 for shearing the flow offluidic materials therein are illustrated. The baffle assemblies 900include commercially available static mixers that cause shearing offluids flowing through the flow passages defined by the baffleassemblies.

Referring now to FIG. 31, an exemplary embodiment of a system 3100 forheating and vaporizing fluidic materials includes a vessel 3102 thatdefines an inner chamber 3102 a for containing fluidic materials 3104. Asource 3106 of fluidic materials is operably coupled to a lower endportion of the vessel 3102 by an inlet passage 3108. One or more heaterelements 3110 are positioned within the lower end portion of the vessel3102 which are also operably coupled to a controller 3112 forcontrolling the operation of the heater elements.

A passage 3114 connects the lower end portion of the vessel 3102 with alevel controller 3116 that is operably coupled to the controller 3112. Apassage 3118 connects the level controller 3116 with an upper endportion of the vessel 3102 proximate an open end 3120 a of a vessel 3120positioned in the upper end portion of the vessel 3102. In an exemplaryembodiment, the level controller 3116 includes one or more flow controlvalves for controlling the flow of fluidic materials from the passage3114 to the passage 3118. One or more heater elements 3122 arepositioned within the vessel 3120 which are also operably coupled to acontroller 3112 for controlling the operation of the heater elements.

A passage 3124 connects another end portion of the vessel 3120 forexhausting fluidic materials from the system 3100 for use by anotherdevice. A temperature sensor 3126 is operably coupled to the passage3124 and the controller 3112 for generating signals representative ofthe operating temperature of the fluidic materials within the passage3124.

In an exemplary embodiment, during the operation of the system 3100,fluidic materials are conveyed from the source 3106 through the passage3108 and into the lower end portion of the vessel 3102. In an exemplaryembodiment, the fluidic materials within the source 3106 may includesliquid and/or gaseous materials. Within the vessel 3102, the fluidicmaterials are heated by operation of the heater elements 3110 under thecontrol of the controller 3112. In an exemplary embodiment, heating ofthe fluidic materials within the lower end portion of the vessel 3102 byoperation of the heater elements 3110 pressurizes the inner chamber 3102a of the vessel and may also, at least to some extent, vaporize at leasta portion of the fluidic materials therein.

In an exemplary embodiment, fluidic materials within the lower endportion of the vessel 3102 may then be conveyed into the interior of theupper end of the vessel 3102 a wherein at least a portion of the fluidicmaterials may enter the open end 3120 a of the vessel 3120 through thepassages 3114 and 3118 by operation of the level controller 3116 underthe control of the controller 3112. The fluidic materials that areconveyed into the interior of the vessel 3120 are then heated byoperation of the heater elements 3122. In an exemplary embodiment,heating of the fluidic materials within the interior of the vessel 3120by operation of the heater elements 3122 will further pressurize thefluidic materials and may also completely vaporize the materialstherein.

The materials within the interior of the vessel 3120 may then beconveyed out of the vessel through the passage 3124 for furtherprocessing and/or use. In an exemplary embodiment, the operatingtemperature of the materials within the passage 3124 are monitored bythe temperature sensor 3126. In this manner, feedback control of thesystem 3100 may be provided in which a desired operating temperature ofthe materials within the passage 3124 is used as a set point in afeedback control system implemented by the controller 3112 that may, forexample, be a second order feedback control system.

Referring now to FIGS. 32 and 33, an exemplary embodiment of a system3200 for heating and vaporizing fluidic materials includes a vessel 3202that defines an inner chamber 3202 a for containing fluidic materials3204. A source 3206 of fluidic materials is operably coupled to a lowerend portion of the vessel 3202 by an inlet passage 3208, a flow controlvalve 3210 and an inlet passage 3212. In an exemplary embodiment, theflow control valve 3210 is also operably coupled to a controller 3214for controlling the operation of the flow control valve. One or moreheater elements 3216 are positioned within the lower end portion of thevessel 3202 which are also operably coupled to the controller 3214 forcontrolling the operation of the heater elements.

A passage 3218 connects the lower end portion of the vessel 3202 with alevel controller 3220 that may also be operably coupled to thecontroller 3214. A passage 3222 connects the level controller 3220 withan upper end portion of the vessel 3202 proximate an open end 3224 a ofa vessel 3224 positioned with an upper portion of the vessel 3202. In anexemplary embodiment, the level controller 3220 includes one or moreflow control valves for controlling the flow of fluidic materials fromthe passage 3218 to the passage 3222. One or more heater elements 3226are positioned within the vessel 3224 which are also operably coupled tothe controller 3214 for controlling the operation of the heaterelements.

A passage 3228 connects another end portion of the vessel 3224 forexhausting fluidic materials from the system 3200 for use by anotherdevice. A temperature sensor 3230 and a pressure sensor 3232 areoperably coupled to the passage 3228 and the controller 3214 forgenerating signals representative of the operating temperature andpressure of the fluidic materials within the passage 3228. A pressurerelief valve 3234 is also operably coupled to the passage 3228 forreleasing pressure from the passage if the operating pressure exceedsthe set point of the valve.

In an exemplary embodiment, as illustrated in FIG. 33, in an exemplaryembodiment, the vessel 3224 includes at least one drainage passage 3224b defined in a lower end portion of the vessel for allowing liquids todrain out of the vessel 3224. In an exemplary embodiment, the vessel3224 further includes a coalescing filter material 3236 positionedwithin the vessel that also surrounds at least some of the heaterelements 3226 positioned within the vessel for enhancing the coalescenceof liquid droplets within the vessel that may then be exhausted from thevessel through the passages 3224 b.

In an exemplary embodiment, during the operation of the system 3200,fluidic materials are conveyed from the source 3206 through the passage3208, the flow control valve 3210 and the passage 3212 and into thelower end portion of the vessel 3202. In an exemplary embodiment, thefluidic materials within the source 3206 may includes liquid and/orgaseous materials. Within the vessel 3202, the fluidic materials areheated by operation of the heater elements 3216 under the control of thecontroller 3214. In an exemplary embodiment, heating of the fluidicmaterials within the lower end portion of the vessel 3202 by operationof the heater elements 3216 pressurizes the inner chamber 3202 a of thevessel and may also, at least to some extent, vaporize at least aportion of the fluidic materials therein.

In an exemplary embodiment, fluidic materials within the lower endportion of the vessel 3202 may then be conveyed into the interior of theupper end portion of the vessel 3202 through the passages 3218 and 3222by operation of the level controller 3220 under the control of thecontroller 3214. In an exemplary embodiment, at least a portion of thefluidic materials that are conveyed into the interior of the upper endportion of the vessel 3202 may thereby enter the open end 3224 a of thevessel 3224. In an exemplary embodiment, the amount of fluidic materialswithin the vessel 3202 is further controlled by operation of the flowcontrol valve 3210 and/or the level controller 3220.

The fluidic materials that are conveyed into the interior of the vessel3224 are then heated by operation of the heater elements 3226. In anexemplary embodiment, heating of the fluidic materials within theinterior of the vessel 3224 by operation of the heater elements 3226will further pressurize the fluidic materials and may also completelyvaporize the materials therein. In an exemplary embodiment, liquiddroplets may coalesce on the coalescing filter 3236 within the vessel3224 and be exhausted from the vessel through the passages 3224 b. In anexemplary embodiment, during operation, the coalescing filter 3236permits more heavy components, e.g., liquid droplets, to be separatedfrom the flow stream which may also lower the dew point of the remainingcomponents of the flow stream.

The materials within the interior of the vessel 3224 may then beconveyed out of the vessel through the passage 3228 for furtherprocessing and/or use. In an exemplary embodiment, the operatingtemperature and/or pressure of the materials within the passage 3228 aremonitored by the temperature and pressure sensors, 3230 and 3232. Inthis manner, feedback control of the system 3200 may be provided inwhich a desired operating temperature and/or pressure of the materialswithin the passage 3228 are used as set points in a feedback controlsystem implemented by the controller 3214 that may, for example, be asecond order feedback control system.

In an exemplary embodiment, the systems 3100 and 3200 may include oromit one or more elements of the exemplary embodiments of the presentdisclosure.

Referring now to FIG. 34, an exemplary experimental embodiment of thesystem 3100 was created using a numerical model that was predictive ofoperational results that illustrates heating and boiling of the fluidicmaterials 3104 within the inner chamber 3102 a of the vessel 3102.

Referring now to FIG. 35, an exemplary experimental embodiment of thesystem 3100 was created using a numerical model that was predictive ofoperational results that illustrates the operating temperature of theheater elements 3110 during the heating and boiling of the fluidicmaterials 3104 within the inner chamber 3102 a of the vessel 3102.

Referring now to FIG. 36, an exemplary experimental embodiment of thesystem 3100 was created using a numerical model that was predictive ofoperational results that illustrates the operating temperature of thesuperheated gas within the inner chamber 3102 a of the vessel 3102 andwithin the vessel 3120.

Referring now to FIG. 37, an exemplary experimental embodiment of thesystem 3100 was created using a numerical model that was predictive ofoperational results that illustrates the operating temperature of theheating elements 3122 within the vessel 3120 during the superheating ofthe gas within the inner chamber 3102 a of the vessel 3102 and withinthe vessel 3120.

The exemplary experimental results illustrated in FIGS. 34-37 wereunexpected.

In an exemplary embodiment, during operation of the system 3100,sub-cooled liquid enters the bottom portion of the vessel 3102. Theheating elements 3110 then raise enthalpy of the liquid until it boils.Saturated vapor then enters the open end 3120 a of the vessel 3120.Operation of the heating elements 3122 within the vessel 3120 thensuperheat the vapor to at least about 50° F. above the dew point.

In an exemplary embodiment, during operation of the system 3200,sub-cooled liquid enters the bottom portion of the vessel 3202. Theheating elements 3216 then raise enthalpy of the liquid until it boils.Saturated vapor then enters the open end 3224 a of the vessel 3224.Operation of the heating elements 3226 within the vessel 3224 thensuperheat the vapor to at least about 50° F. above the dew point.

In an exemplary embodiment, as illustrated in FIG. 38, the vessel 3120of the system 3100 that contains the heating elements 3122 includes aplurality of spaced apart slots 3122 b on a bottom portion and one ormore mesh pads 3122 c are positioned within the interior of the vessel3120. In an exemplary embodiment, during operation of the system 3100,as entrained liquid droplets pass through the heated mesh pad 3122 c,the lighter molecules vaporize and the heavier molecules coalesce andfall through the slots 3122 b provided in the bottom wall of the vessel3120. As a result, the separation process yields a greater than onestage of separation, less heat is required to super heat the saturatedgas vapor, and the mess pads 3122 c enhance the transfer of heat fromthe heating elements 3122 to the gas vapor.

Referring now to FIG. 39, an exemplary embodiment of a distillationcolumn assembly 3900 includes a plurality of heaters 3902, one or moreof which may include one or more of the systems 3100 and/or 3200, thatare coupled in series between a reboiler 3904 and a condenser 3906 toprovide a multi-stage distillation column. In particular, the outlet ofeach of the systems 3100 and/or 3200 are operably coupled to the inletof the next systems 3100 and/or 3200 in series fashion. The generaldesign and operation of distillation column assemblies, other than thedesign and operation of the systems 3100 and/or 3200, is well known topersons having ordinary skill in the art. During operation, the outletof each of the systems 3100 and/or 3200 are used to provide a source ofa hydrocarbon fraction. Thus, the systems 3100 and/or 3200 provide amore effective, efficient and controlled substitute for the conventionalfractioning stages that are employed in a multi-stage distillationcolumn. In this manner, different hydrocarbon components may beextracted within each heater 3902 of the assembly 3900.

An apparatus for conditioning feed gas has been described that includesan outer tubular housing; an inner tubular housing that defines apassageway positioned within the outer tubular housing, wherein an endof the passageway is adapted to be operably coupled to an outlet streamof fluidic materials; a plurality of spaced apart baffles positionedwithin the passageway of the inner tubular housing, wherein each baffledefines at least one passageway; one or more heating elements positionedwithin the passageway of the inner tubular housing, wherein each heatingelement extends through a corresponding passageway in each of thebaffles; and an annular passageway defined between the inner and outertubular housings, wherein an inlet of the annular passageway is adaptedto be operably coupled to an input stream of fluidic material, andwherein an outlet of the annular passageway is operably coupled toanother end of the passageway of the inner tubular housing. In anexemplary embodiment, the outer tubular housing ranges from 4 inch,schedule 40 pipe to 24 inch, schedule 40 pipe; and wherein the innertubular housing ranges from 3 inch, schedule 10 pipe to 20 inch,schedule 10 pipe. In an exemplary embodiment, the outer tubular housingis fabricated from materials selected from the group consisting of lowcarbon steel, 304 stainless steel, and 304H stainless steel; and theinner tubular housing is fabricated from materials selected from thegroup consisting of H grade stainless steel, 316H stainless steel, andchromoly steel. In an exemplary embodiment, the spacing of the bafflesin a longitudinal direction within the passageway of the inner tubularhousing ranges from about 2 to 60 inches. In an exemplary embodiment,the spacing of the baffles in a longitudinal direction within thepassageway of the inner tubular housing is about equal to the internaldiameter of the inner tubular housing. In an exemplary embodiment, theinternal diameters of the passageways of the baffles are greater thanthe external diameters of the corresponding heating elements. In anexemplary embodiment, the internal diameters of the passageways of thebaffles are at least about 10% greater than the external diameters ofthe corresponding heating elements. In an exemplary embodiment, thenumber of heating elements ranges from about 3 to 360. In an exemplaryembodiment, the average center-to-center spacing of the heating elementsranges from about 1 to 5 inches. In an exemplary embodiment, the outsidediameter of the heating elements are about 0.475 inches and the insidediameters of the passages, 214 a and 216 a, through the baffles, 214 and216, are about 1/16^(th) to about ¼^(th) of an inch larger. In anexemplary embodiment, the inside diameters of the passages, 214 a and216 a, through the baffles, 214 and 216, are at least ¼^(th) of an inchlarger in diameter to allow for easier assembly.

A method for conditioning feed gas has been described that includesfeeding an inlet stream of gas into an outer passageway in a firstdirection; then feeding the inlet stream of gas into an inner passagewayin a second direction, in opposition to the first direction; heating theinlet stream of gas within the inner passageway; and impeding the flowof the inlet stream of gas within the inner passageway. In an exemplaryembodiment, the method further includes heating the inlet stream of gaswithin the outer passageway. In an exemplary embodiment, the methodfurther includes heating the inlet stream of gas within the outerpassageway by transmitting heat from the inlet stream of gas within theinner passageway. In an exemplary embodiment, heating the inlet streamof gas within the inner passageway includes positioning a plurality ofheating elements within the inner passageway. In an exemplaryembodiment, impeding the flow of the inlet stream of gas within theinner passageway includes constricting the flow of the inlet stream ofgas proximate the heating elements within the inner passageway. In anexemplary embodiment, impeding the flow of the inlet stream of gaswithin the inner passageway includes constricting the flow of the inletstream of gas within the inner passageway.

An apparatus for conditioning feed gas has been described that includesan outer tubular housing; an inner tubular housing that defines apassageway and is positioned within the outer tubular housing, whereinan end of the passageway is adapted to be operably coupled to an outletstream of fluidic materials; a plurality of baffle assemblies positionedwithin the passageway of the inner tubular housing; one or more heatingelements positioned within the passageway of the inner tubular housing;and an annular passageway defined between the inner and outer tubularhousings, wherein an inlet of the annular passageway is adapted to beoperably coupled to an inlet stream of fluidic material, and wherein anoutlet of the annular passageway is operably coupled to another end ofthe passageway of the inner tubular housing; wherein one or more of thebaffle assemblies comprise a first baffle element and a second baffleelement; wherein the first and second baffle elements each define one ormore passages; wherein the first and second baffle elements arepositioned in different planes; and wherein one or more of the heatingelements extend through one or more of the passageways of one or more ofthe first and second baffle elements of one or more of the baffleassemblies. In an exemplary embodiment, the outer tubular housing rangesfrom 4 inch, schedule 40 pipe to 24 inch, schedule 40 pipe; and whereinthe inner tubular housing ranges from 3 inch, schedule 10 pipe to 20inch, schedule 10 pipe. In an exemplary embodiment, the outer tubularhousing is fabricated from materials selected from the group consistingof low carbon steel, 304 stainless steel, and 304H stainless steel; andwherein the inner tubular housing is fabricated from materials selectedfrom the group consisting of H grade stainless steel, 316H stainlesssteel, and chromoly steel. In an exemplary embodiment, the spacing ofthe baffles in a longitudinal direction within the passageway of theinner tubular housing ranges from about 2 to 60 inches. In an exemplaryembodiment, the spacing of the baffle assemblies in a longitudinaldirection within the passageway of the inner tubular housing is aboutequal to the internal diameter of the inner tubular housing. In anexemplary embodiment, the internal diameters of the passageways of thefirst and second baffle elements are greater than the external diametersof the corresponding heating elements. In an exemplary embodiment, theinternal diameters of the passageways of the first and second baffleelements are at least about 10% greater than the external diameters ofthe corresponding heating elements. In an exemplary embodiment, thenumber of heating elements ranges from about 3 to 360. In an exemplaryembodiment, the average center to center spacing of the heating elementsranges from about 1 to 5 inches. In an exemplary embodiment, the outsidediameters of the heating elements are about 0.475 inches and the insidediameters of the corresponding passageways through the first and secondbaffle elements are about 1/16^(th) to about ¼^(th) of an inch larger indiameter. In an exemplary embodiment, the inside diameters of thecorresponding passageways through the first and second baffle elementsare at least about ¼^(th) of an inch larger in diameter to allow foreasier assembly. In an exemplary embodiment, each of the first andsecond baffle elements comprise an outer peripheral arcuate portion thatmates with the inner tubular housing and another outer peripheralportion that does not mate with the inner tubular housing. In anexemplary embodiment, the baffle assemblies and the inner tubularhousing define a serpentine flow path for the passage of fluidicmaterials therethrough. In an exemplary embodiment, the angular spacingbetween the planes of the first and second baffle elements ranges fromabout 15 to 75 degrees. In an exemplary embodiment, the lateral spacingof the baffle assemblies within the passageway of the inner tubularhousing ranges from intimate contact to about several times the internaldiameter of the inner tubular housing. In an exemplary embodiment, thebaffle assemblies are adapted to shear the flow of fluidic materialswithin the passageway of the inner tubular housing. In an exemplaryembodiment, the baffle assemblies are adapted to cause the fluidicmaterials within the passageway of the inner tubular housing to flowover the heating elements at an angle to the heating elements. In anexemplary embodiment, the baffle assemblies are adapted to cause thefluidic materials within the passageway of the inner tubular housing tomix over the heating elements at an angle to the heating elements.

A method for conditioning feed gas has been described that includesfeeding an inlet stream of gas into an outer passageway in a firstdirection; then feeding the inlet stream of gas into an innerpassageway, positioned within the outer passageway, in a seconddirection, in opposition to the first direction; heating the inletstream of gas within the inner passageway; and impeding the flow of theinlet stream of gas within the inner passageway using a plurality ofbaffle elements that are positioned in different planes. In an exemplaryembodiment, the method further includes heating the inlet stream of gaswithin the outer passageway. In an exemplary embodiment, the methodfurther includes heating the inlet stream of gas within the outerpassageway by transmitting heat from the inlet stream of gas within theinner passageway. In an exemplary embodiment, heating the inlet streamof gas within the inner passageway includes positioning a plurality ofheating elements within the inner passageway. In an exemplaryembodiment, impeding the flow of the inlet stream of gas within theinner passageway includes constricting the flow of the inlet stream ofgas proximate the heating elements within the inner passageway. In anexemplary embodiment, impeding the flow of the inlet stream of gaswithin the inner passageway includes constricting the flow of the inletstream of gas within the inner passageway. In an exemplary embodiment,impeding the flow of the inlet stream of gas within the inner passagewayincludes creating a serpentine flow of the inlet stream of gas withinthe inner passageway. In an exemplary embodiment, impeding the flow ofthe inlet stream of gas within the inner passageway further includesconstricting the flow of the inlet stream of gas proximate the heatingelements within the inner passageway. In an exemplary embodiment, theangular spacing between the planes of the baffle elements ranges fromabout 15 to 75 degrees. In an exemplary embodiment, the lateral spacingof the baffle elements within the inner passageway ranges from intimatecontact to about several times the internal diameter of the innertubular housing. In an exemplary embodiment, the method further includesshearing the flow of the inlet stream of gas within the innerpassageway. In an exemplary embodiment, the method further includesflowing the inlet stream of gas within the inner passageway at an angleover one or more heating elements. In an exemplary embodiment, themethod further includes mixing the inlet stream of gas within the innerpassageway over one or more heating elements. In an exemplaryembodiment, heating the inlet stream of gas within the inner passagewayincludes providing one or more heating elements within the innerpassageway; and wherein impeding the flow of the inlet stream of gaswithin the inner passageway includes causing the inlet stream of gas toflow in a direction transverse to the heating elements.

A system for conditioning feed gas has been described that includesmeans for feeding an inlet stream of gas into an outer passageway in afirst direction; means for then feeding the inlet stream of gas into aninner passageway in a second direction, in opposition to the firstdirection; means for heating the inlet stream of gas within the innerpassageway; and means for impeding the flow of the inlet stream of gaswithin the inner passageway. In an exemplary embodiment, the systemfurther includes means for heating the inlet stream of gas within theouter passageway. In an exemplary embodiment, the system furtherincludes means for heating the inlet stream of gas within the outerpassageway by transmitting heat from the inlet stream of gas within theinner passageway. In an exemplary embodiment, the means for heating theinlet stream of gas within the inner passageway comprises means forpositioning a plurality of heating elements within the inner passageway.In an exemplary embodiment, the means for impeding the flow of the inletstream of gas within the inner passageway comprises means forconstricting the flow of the inlet stream of gas proximate the heatingelements within the inner passageway. In an exemplary embodiment, themeans for impeding the flow of the inlet stream of gas within the innerpassageway includes means for constricting the flow of the inlet streamof gas within the inner passageway. In an exemplary embodiment, themeans for impeding the flow of the inlet stream of gas within the innerpassageway includes means for creating a serpentine flow of the inletstream of gas within the inner passageway. In an exemplary embodiment,the means for impeding the flow of the inlet stream of gas within theinner passageway further includes means for constricting the flow of theinlet stream of gas proximate the heating elements within the innerpassageway. In an exemplary embodiment, the system further includesmeans for shearing the flow of the inlet stream of gas within the innerpassageway. In an exemplary embodiment, the system further includesmeans for flowing the inlet stream of gas within the inner passageway atan angle to heating elements. In an exemplary embodiment, the systemfurther includes means for mixing the inlet stream of gas within theinner passageway over heating elements. In an exemplary embodiment,means for heating the inlet stream of gas within the inner passagewaycomprises means for providing one or more heating elements within theinner passageway; and wherein means for impeding the flow of the inletstream of gas within the inner passageway comprises means for causingthe inlet stream of gas to flow in a direction transverse to the heatingelements.

A baffle assembly for use in a tubular housing has been described thatincludes a first baffle element that defines one or more firstpassageways; a second baffle element that defines one or more secondpassageways; and a hinge coupled between the first and second baffleelements for permitting the first and second baffle elements to bepositioned in different planes; wherein the first baffle elementcomprises an outer peripheral arcuate portion that mates with a portionof the interior surface of the tubular housing and another peripheralportion that does not mate with the interior surface of the tubularhousing; and wherein the second baffle element comprises an outerperipheral arcuate portion that mates with a portion of the interiorsurface of the tubular housing and another peripheral portion that doesnot mate with the interior surface of the tubular housing. In anexemplary embodiment, when the first and second baffle elements arepositioned in a common plane, the baffle assembly includes a circularouter peripheral profile. In an exemplary embodiment, when the first andsecond baffle elements are positioned in a common plane, the baffleassembly comprises a semi-circular outer peripheral profile. In anexemplary embodiment, the hinge defines one or more passageways. In anexemplary embodiment, the hinge includes a base member; a first hingecoupled to the base member for pivoting the first baffle element; and asecond hinge coupled to the base member for pivoting the second baffleelement. In an exemplary embodiment, the baffle assembly furtherincludes a third baffle element pivotally coupled to the hinge thatdefines one or more third passageways; and a fourth baffle elementpivotally coupled to the hinge that defines one or more fourthpassageways; wherein the third baffle element comprises an outerperipheral arcuate portion that mates with a portion of the interiorsurface of the tubular housing and another peripheral portion that doesnot mate with the interior surface of the tubular housing; and whereinthe fourth baffle element comprises an outer peripheral arcuate portionthat mates with a portion of the interior surface of the tubular housingand another peripheral portion that does not mate with the interiorsurface of the tubular housing. In an exemplary embodiment, the first,second, third and further baffle elements may be positioned incorresponding different planes.

A method for conditioning feed gas has been described that includesheating an inlet stream of gas within a passageway; and impeding theflow of the inlet stream of gas within the passageway using a pluralityof baffle elements that are positioned in different planes. In anexemplary embodiment, heating the inlet stream of gas within thepassageway includes positioning a plurality of heating elements withinthe passageway. In an exemplary embodiment, impeding the flow of theinlet stream of gas within the passageway includes constricting the flowof the inlet stream of gas proximate the heating elements within thepassageway. In an exemplary embodiment, impeding the flow of the inletstream of gas within the passageway includes constricting the flow ofthe inlet stream of gas within the passageway. In an exemplaryembodiment, impeding the flow of the inlet stream of gas within thepassageway includes creating a serpentine flow of the inlet stream ofgas within the passageway. In an exemplary embodiment, impeding the flowof the inlet stream of gas within the passageway further includesconstricting the flow of the inlet stream of gas proximate the heatingelements within the passageway. In an exemplary embodiment, the angularspacing between the planes of the baffle elements ranges from about 15to 75 degrees. In an exemplary embodiment, the lateral spacing of thebaffle elements within the passageway ranges from intimate contact toabout several times the internal diameter of the passageway. In anexemplary embodiment, the method further includes shearing the flow ofthe inlet stream of gas within the passageway. In an exemplaryembodiment, the method further includes flowing the inlet stream of gaswithin the passageway at an angle over one or more heating elements. Inan exemplary embodiment, the method further includes mixing the inletstream of gas within the passageway over one or more heating elements.In an exemplary embodiment, heating the inlet stream of gas within thepassageway includes providing one or more heating elements within thepassageway; and impeding the flow of the inlet stream of gas within thepassageway includes causing the inlet stream of gas to flow in adirection transverse to the heating elements.

A system for conditioning feed gas has been described that includesmeans for heating an inlet stream of gas within a passageway; and meansfor impeding the flow of the inlet stream of gas within the passagewayusing a plurality of baffle elements that are positioned in differentplanes. In an exemplary embodiment, the means for heating the inletstream of gas within the passageway includes means for positioning aplurality of heating elements within the passageway. In an exemplaryembodiment, the means for impeding the flow of the inlet stream of gaswithin the passageway includes means for constricting the flow of theinlet stream of gas proximate the heating elements within thepassageway. In an exemplary embodiment, the means for impeding the flowof the inlet stream of gas within the passageway includes means forconstricting the flow of the inlet stream of gas within the passageway.In an exemplary embodiment, the means for impeding the flow of the inletstream of gas within the passageway includes means for creating aserpentine flow of the inlet stream of gas within the passageway. In anexemplary embodiment, the means for impeding the flow of the inletstream of gas within the passageway further includes means forconstricting the flow of the inlet stream of gas proximate the heatingelements within the passageway. In an exemplary embodiment, the angularspacing between the planes of the baffle elements ranges from about 15to 75 degrees. In an exemplary embodiment, the lateral spacing of thebaffle elements within the passageway ranges from intimate contact toabout several times the internal diameter of the passageway. In anexemplary embodiment, the system further includes means for shearing theflow of the inlet stream of gas within the passageway. In an exemplaryembodiment, the system further includes means for flowing the inletstream of gas within the passageway at an angle over one or more heatingelements. In an exemplary embodiment, the system further includes meansfor mixing the inlet stream of gas within the passageway over one ormore heating elements. In an exemplary embodiment, the means for heatingthe inlet stream of gas within the passageway includes providing one ormore heating elements within the passageway; and the means for impedingthe flow of the inlet stream of gas within the passageway includescausing the inlet stream of gas to flow in a direction transverse to theheating elements.

An apparatus for conditioning feed gas has been described that includesan outer tubular housing; an inner tubular housing that defines apassageway and is positioned within the outer tubular housing, whereinan end of the passageway is adapted to be operably coupled to an outletstream of fluidic materials; a plurality of baffle assemblies positionedwithin the passageway of the inner tubular housing; one or more heatingelements positioned within the passageway of the inner tubular housing;and an annular passageway defined between the inner and outer tubularhousings, wherein an inlet of the annular passageway is adapted to beoperably coupled to an inlet stream of fluidic material, and wherein anoutlet of the annular passageway is operably coupled to another end ofthe passageway of the inner tubular housing; wherein one or more of thebaffle assemblies comprise a first baffle element and a second baffleelement; wherein the first and second baffle elements each define one ormore passages; wherein the first and second baffle elements arepositioned in different planes; and wherein one or more of the heatingelements extend through one or more of the passageways of one or more ofthe first and second baffle elements of one or more of the baffleassemblies. In an exemplary embodiment, the outer tubular housing rangesfrom 4 inch, schedule 40 pipe to 24 inch, schedule 40 pipe; and theinner tubular housing ranges from 3 inch, schedule 10 pipe to 20 inch,schedule 10 pipe. In an exemplary embodiment, the outer tubular housingis fabricated from materials selected from the group consisting of lowcarbon steel, 304 stainless steel, and 304H stainless steel; and theinner tubular housing is fabricated from materials selected from thegroup consisting of H grade stainless steel, 316H stainless steel, andchromoly steel. In an exemplary embodiment, the spacing of the bafflesin a longitudinal direction within the passageway of the inner tubularhousing ranges from about 2 to 60 inches. In an exemplary embodiment,the spacing of the baffle assemblies in a longitudinal direction withinthe passageway of the inner tubular housing is about equal to theinternal diameter of the inner tubular housing. In an exemplaryembodiment, the internal diameters of the passageways of the first andsecond baffle elements are greater than the external diameters of thecorresponding heating elements. In an exemplary embodiment, the internaldiameters of the passageways of the first and second baffle elements areat least about 10% greater than the external diameters of thecorresponding heating elements. In an exemplary embodiment, the numberof heating elements ranges from about 3 to 360. In an exemplaryembodiment, the average center to center spacing of the heating elementsranges from about 1 to 5 inches. In an exemplary embodiment, the outsidediameters of the heating elements are about 0.475 inches and the insidediameters of the corresponding passageways through the first and secondbaffle elements are about 1/16^(th) to about ¼^(th) of an inch larger indiameter. In an exemplary embodiment, the inside diameters of thecorresponding passageways through the first and second baffle elementsare at least about ¼^(th) of an inch larger in diameter to allow foreasier assembly. In an exemplary embodiment, each of the first andsecond baffle elements comprise an outer peripheral arcuate portion thatmates with the inner tubular housing and another outer peripheralportion that does not mate with the inner tubular housing. In anexemplary embodiment, the baffle assemblies and the inner tubularhousing define a serpentine flow path for the passage of fluidicmaterials therethrough. In an exemplary embodiment, the angular spacingbetween the planes of the first and second baffle elements ranges fromabout 15 to 75 degrees. In an exemplary embodiment, the lateral spacingof the baffle assemblies within the passageway of the inner tubularhousing ranges from intimate contact to about several times the internaldiameter of the inner tubular housing. In an exemplary embodiment, thebaffle assemblies are adapted to shear the flow of fluidic materialswithin the passageway of the inner tubular housing. In an exemplaryembodiment, the baffle assemblies are adapted to cause the fluidicmaterials within the passageway of the inner tubular housing to flowover the heating elements at an angle to the heating elements. In anexemplary embodiment, the baffle assemblies are adapted to cause thefluidic materials within the passageway of the inner tubular housing tomix over the heating elements at an angle to the heating elements. In anexemplary embodiment, a heat transfer coefficient within the innertubular housing ranges from about 12.3 to about 33 Btu/hr*ft²*° F. In anexemplary embodiment, an operating temperature of the heating elementsranges from about 757 to about 1147° F. In an exemplary embodiment, aheat transfer coefficient within the inner tubular housing ranges fromabout 12.3 to about 33 Btu/hr*ft²*° F.; and an operating temperature ofthe heating elements ranges from about 757 to about 1147° F.

A method for conditioning feed gas has been described that includesfeeding an inlet stream, of gas into an outer passageway in a firstdirection; then feeding the inlet stream of gas into an innerpassageway, positioned within the outer passageway, in a seconddirection, in opposition to the first direction; heating the inletstream of gas within the inner passageway; and impeding the flow of theinlet stream of gas within the inner passageway using a plurality ofbaffle elements that are positioned in different planes. In an exemplaryembodiment, the method further includes heating the inlet stream of gaswithin the outer passageway. In an exemplary embodiment, the methodfurther includes heating the inlet stream of gas within the outerpassageway by transmitting heat from the inlet stream of gas within theinner passageway. In an exemplary embodiment, heating the inlet streamof gas within the inner passageway comprises positioning a plurality ofheating elements within the inner passageway. In an exemplaryembodiment, impeding the flow of the inlet stream of gas within theinner passageway comprises constricting the flow of the inlet stream ofgas proximate the heating elements within the inner passageway. In anexemplary embodiment, impeding the flow of the inlet stream of gaswithin the inner passageway comprises constricting the flow of the inletstream of gas within the inner passageway. In an exemplary embodiment,impeding the flow of the inlet stream of gas within the inner passagewaycomprises creating a serpentine flow of the inlet stream of gas withinthe inner passageway. In an exemplary embodiment, impeding the flow ofthe inlet stream of gas within the inner passageway further comprisesconstricting the flow of the inlet stream of gas proximate the heatingelements within the inner passageway. In an exemplary embodiment, theangular spacing between the planes of the baffle elements ranges fromabout 15 to 75 degrees. In an exemplary embodiment, the lateral spacingof the baffle elements within the inner passageway ranges from intimatecontact to about several times the internal diameter of the innertubular housing. In an exemplary embodiment, the method further includesshearing the flow of the inlet stream of gas within the innerpassageway. In an exemplary embodiment, the method further includesflowing the inlet stream of gas within the inner passageway at an angleover one or more heating elements. In an exemplary embodiment, themethod further includes mixing the inlet stream of gas within the innerpassageway over one or more heating elements. In an exemplaryembodiment, heating the inlet stream of gas within the inner passagewaycomprises providing one or more heating elements within the innerpassageway; and impeding the flow of the inlet stream of gas within theinner passageway comprises causing the inlet stream of gas to flow in adirection transverse to the heating elements. In an exemplaryembodiment, a heat transfer coefficient within the inner passagewayranges from about 12.3 to about 33 Btu/hr*ft²*° F. In an exemplaryembodiment, heating the inlet stream within the inner passagewaycomprises positioning one or more heating elements within the innerpassageway; and wherein an operating temperature of the heating elementsranges from about 757 to about 1147° F. In an exemplary embodiment,heating the inlet stream within the inner passageway comprisespositioning one or more heating elements within the inner passageway; aheat transfer coefficient within the inner passageway ranges from about12.3 to about 33 Btu/hr*ft²*° F.; and an operating temperature of theheating elements ranges from about 757 to about 1147° F.

A system for conditioning feed gas has been described that includesmeans for feeding an inlet stream of gas into an outer passageway in afirst direction; means for then feeding the inlet stream of gas into aninner passageway in a second direction, in opposition to the firstdirection; means for heating the inlet stream of gas within the innerpassageway; and means for impeding the flow of the inlet stream of gaswithin the inner passageway. In an exemplary embodiment, the systemfurther includes means for heating the inlet stream of gas within theouter passageway. In an exemplary embodiment, the system furtherincludes means for heating the inlet stream of gas within the outerpassageway by transmitting heat from the inlet stream of gas within theinner passageway. In an exemplary embodiment, means for heating theinlet stream of gas within the inner passageway comprises means forpositioning a plurality of heating elements within the inner passageway.In an exemplary embodiment, means for impeding the flow of the inletstream of gas within the inner passageway comprises means forconstricting the flow of the inlet stream of gas proximate the heatingelements within the inner passageway. In an exemplary embodiment, meansfor impeding the flow of the inlet stream of gas within the innerpassageway comprises means for constricting the flow of the inlet streamof gas within the inner passageway. In an exemplary embodiment, meansfor impeding the flow of the inlet stream of gas within the innerpassageway comprises means for creating a serpentine flow of the inletstream of gas within the inner passageway. In an exemplary embodiment,means for impeding the flow of the inlet stream of gas within the innerpassageway comprises means for constricting the flow of the inlet streamof gas proximate the heating elements within the inner passageway. In anexemplary embodiment, the system further includes means for shearing theflow of the inlet stream of gas within the inner passageway. In anexemplary embodiment, the system further includes means for flowing theinlet stream of gas within the inner passageway at an angle to heatingelements. In an exemplary embodiment, the system further includes meansfor mixing the inlet stream of gas within the inner passageway overheating elements. In an exemplary embodiment, means for heating theinlet stream of gas within the inner passageway comprises means forproviding one or more heating elements within the inner passageway; andmeans for impeding the flow of the inlet stream of gas within the innerpassageway comprises means for causing the inlet stream of gas to flowin a direction transverse to the heating elements. In an exemplaryembodiment, a heat transfer coefficient within the inner passagewayranges from about 12.3 to about 33 Btu/hr*ft²*° F. In an exemplaryembodiment, an operating temperature of the means for heating the inletstream of gas within the inner passageway ranges from about 757 to about1147° F. In an exemplary embodiment, a heat transfer coefficient withinthe inner passageway ranges from about 12.3 to about 33 Btu/hr*ft²*° F.;and an operating temperature of the means for heating the inlet streamof gas within the inner passageway ranges from about 757 to about 1147°F.

A baffle assembly for use in a tubular housing has been described thatincludes a first baffle element that defines one or more firstpassageways; a second baffle element that defines one or more secondpassageways; and a hinge coupled between the first and second baffleelements for permitting the first and second baffle elements to bepositioned in different planes; wherein the first baffle elementcomprises an outer peripheral arcuate portion that mates with a portionof the interior surface of the tubular housing and another peripheralportion that does not mate with the interior surface of the tubularhousing; and wherein the second baffle element comprises an outerperipheral arcuate portion that mates with a portion of the interiorsurface of the tubular housing and another peripheral portion that doesnot mate with the interior surface of the tubular housing. In anexemplary embodiment, the first and second baffle elements arepositioned in a common plane, the baffle assembly comprises a circularouter peripheral profile. In an exemplary embodiment, the first andsecond baffle elements are positioned in a common plane, the baffleassembly comprises a semi-circular outer peripheral profile. In anexemplary embodiment, the hinge defines one or more passageways. In anexemplary embodiment, the hinge comprises a base member; a first hingecoupled to the base member for pivoting the first baffle element; and asecond hinge coupled to the base member for pivoting the second baffleelement. In an exemplary embodiment, the baffle assembly furtherincludes a third baffle element pivotally coupled to the hinge thatdefines one or more third passageways; and a fourth baffle elementpivotally coupled to the hinge that defines one or more fourthpassageways; wherein the third baffle element comprises an outerperipheral arcuate portion that mates with a portion of the interiorsurface of the tubular housing and another peripheral portion that doesnot mate with the interior surface of the tubular housing; and whereinthe fourth baffle element comprises an outer peripheral arcuate portionthat mates with a portion of the interior surface of the tubular housingand another peripheral portion that does not mate with the interiorsurface of the tubular housing. In an exemplary embodiment, the first,second, third and further baffle elements may be positioned incorresponding different planes.

A method for controlling the flow of a feed gas through a passagewaycontaining one or more heating elements has been described that includesimpeding the flow of the inlet stream of gas within the passageway usinga plurality of baffle elements that are positioned in different planes.In an exemplary embodiment, impeding the flow of the inlet stream of gaswithin the passageway comprises constricting the flow of the inletstream of gas proximate the heating elements within the passageway. Inan exemplary embodiment, impeding the flow of the inlet stream of gaswithin the passageway comprises constricting the flow of the inletstream of gas within the passageway. In an exemplary embodiment,impeding the flow of the inlet stream of gas within the passagewaycomprises creating a serpentine flow of the inlet stream of gas withinthe passageway. In an exemplary embodiment, impeding the flow of theinlet stream of gas within the passageway further comprises constrictingthe flow of the inlet stream of gas proximate the heating elementswithin the passageway. In an exemplary embodiment, the angular spacingbetween the planes of the baffle elements ranges from about 15 to 75degrees. In an exemplary embodiment, the lateral spacing of the baffleelements within the passageway ranges from intimate contact to aboutseveral times the internal diameter of the passageway. In an exemplaryembodiment, the method further includes shearing the flow of the inletstream of gas within the passageway. In an exemplary embodiment, themethod further includes flowing the inlet stream of gas within thepassageway at an angle over one or more heating elements. In anexemplary embodiment, the method further includes mixing the inletstream of gas within the passageway over one or more heating elements.In an exemplary embodiment, impeding the flow of the inlet stream of gaswithin the passageway comprises causing the inlet stream of gas to flowin a direction transverse to the heating elements.

A system for controlling the flow of a feed gas through a passagewaycontaining one or more heating elements has been described that includesmeans for introducing the feed gas into the passageway; and means forimpeding the flow of the inlet stream of gas within the passageway usinga plurality of baffle elements that are positioned in different planes.In an exemplary embodiment, means for impeding the flow of the inletstream of gas within the passageway comprises means for constricting theflow of the inlet stream of gas proximate the heating elements withinthe passageway. In an exemplary embodiment, means for impeding the flowof the inlet stream of gas within the passageway comprises means forconstricting the flow of the inlet stream of gas within the passageway.In an exemplary embodiment, means for impeding the flow of the inletstream of gas within the passageway comprises means for creating aserpentine flow of the inlet stream of gas within the passageway. In anexemplary embodiment, means for impeding the flow of the inlet stream ofgas within the passageway further comprises means for constricting theflow of the inlet stream of gas proximate the heating elements withinthe passageway. In an exemplary embodiment, the angular spacing betweenthe planes of the baffle elements ranges from about 15 to 75 degrees. Inan exemplary embodiment, the lateral spacing of the baffle elementswithin the passageway ranges from intimate contact to about severaltimes the internal diameter of the passageway. In an exemplaryembodiment the system further includes means for shearing the flow ofthe inlet stream of gas within the passageway. In an exemplaryembodiment, the system further includes means for flowing the inletstream of gas within the passageway at an angle over one or more heatingelements. In an exemplary embodiment, the system further includes meansfor mixing the inlet stream of gas within the passageway over one ormore heating elements. In an exemplary embodiment, means for impedingthe flow of the inlet stream of gas within the passageway comprisesmeans for causing the inlet stream of gas to flow in a directiontransverse to the heating elements.

An apparatus for conditioning feed gas has been described that includesa tubular housing that defines a passageway, wherein an end of thepassageway is adapted to be operably coupled to an inlet stream offluidic materials and another end of the passageway is adapted to beoperably coupled to an outlet stream of materials; a plurality of baffleassemblies positioned within the passageway of the tubular housing; andone or more heating elements positioned within the passageway of thetubular housing; wherein one or more of the baffle assemblies comprise afirst baffle element and a second baffle element; wherein the first andsecond baffle elements each define one or more passages; wherein thefirst and second baffle elements are positioned in different planes; andwherein one or more of the heating elements extend through one or moreof the passageways of one or more of the first and second baffleelements of one or more of the baffle assemblies. In an exemplaryembodiment, the spacing of the baffles in a longitudinal directionwithin the passageway of the tubular housing ranges from about 2 to 60inches. In an exemplary embodiment, the spacing of the baffle assembliesin a longitudinal direction within the passageway of the tubular housingis about equal to the internal diameter of the tubular housing. In anexemplary embodiment, the internal diameters of the passageways of thefirst and second baffle elements are greater than the external diametersof the corresponding heating elements. In an exemplary embodiment, theinternal diameters of the passageways of the first and second baffleelements are at least about 10% greater than the external diameters ofthe corresponding heating elements. In an exemplary embodiment, thenumber of heating elements ranges from about 3 to 360. In an exemplaryembodiment, the average center to center spacing of the heating elementsranges from about 1 to 5 inches. In an exemplary embodiment, the outsidediameters of the heating elements are about 0.475 inches and the insidediameters of the corresponding passageways through the first and secondbaffle elements are about 1/16^(th) to about ¼^(th) of an inch larger indiameter. In an exemplary embodiment, the inside diameters of thecorresponding passageways through the first and second baffle elementsare at least about ¼^(th) of an inch larger in diameter to allow foreasier assembly. In an exemplary embodiment, each of the first andsecond baffle elements comprise an outer peripheral arcuate portion thatmates with the tubular housing and another outer peripheral portion thatdoes not mate with the tubular housing. In an exemplary embodiment, thebaffle assemblies and the inner tubular housing define a serpentine flowpath for the passage of fluidic materials therethrough. In an exemplaryembodiment, the angular spacing between the planes of the first andsecond baffle elements ranges from about 15 to 75 degrees. In anexemplary embodiment, the lateral spacing of the baffle assemblieswithin the passageway of the tubular housing ranges from intimatecontact to about several times the internal diameter of the tubularhousing. In an exemplary embodiment, the baffle assemblies are adaptedto shear the flow of fluidic materials within the passageway of thetubular housing. In an exemplary embodiment, the baffle assemblies areadapted to cause the fluidic materials within the passageway of thetubular housing to flow over the heating elements at an angle to theheating elements. In an exemplary embodiment, the baffle assemblies areadapted to cause the fluidic materials within the passageway of thetubular housing to mix over the heating elements at an angle to theheating elements. In an exemplary embodiment, a heat transfercoefficient within the tubular housing ranges from about 12.3 to about33 Btu/hr*ft²*° F. In an exemplary embodiment, an operating temperatureof the heating elements ranges from about 757 to about 1147° F. In anexemplary embodiment, a heat transfer coefficient within the tubularhousing ranges from about 12.3 to about 33 Btu/hr*ft²*° F.; and anoperating temperature of the heating elements ranges from about 757 toabout 1147° F.

A method for conditioning feed gas has been described that includesheating an inlet stream of gas within a passageway; and impeding theflow of the inlet stream of gas within the passageway using a pluralityof baffle elements that are positioned in different planes. In anexemplary embodiment, heating the inlet stream of gas within thepassageway comprises positioning a plurality of heating elements withinthe passageway. In an exemplary embodiment, impeding the flow of theinlet stream of gas within the passageway comprises constricting theflow of the inlet stream of gas proximate the heating elements withinthe passageway. In an exemplary embodiment, impeding the flow of theinlet stream of gas within the passageway comprises constricting theflow of the inlet stream of gas within the passageway. In an exemplaryembodiment, impeding the flow of the inlet stream of gas within thepassageway comprises creating a serpentine flow of the inlet stream ofgas within the passageway. In an exemplary embodiment, impeding the flowof the inlet stream of gas within the passageway further comprisesconstricting the flow of the inlet stream of gas proximate the heatingelements within the passageway. In an exemplary embodiment, the angularspacing between the planes of the baffle elements ranges from about 15to 75 degrees. In an exemplary embodiment, the lateral spacing of thebaffle elements within the passageway ranges from intimate contact toabout several times the internal diameter of the passageway. In anexemplary embodiment, the method further includes shearing the flow ofthe inlet stream of gas within the passageway. In an exemplaryembodiment, the method further includes flowing the inlet stream of gaswithin the passageway at an angle over one or more heating elements. Inan exemplary embodiment, the method further includes mixing the inletstream of gas within the passageway over one or more heating elements.In an exemplary embodiment, heating the inlet stream of gas within thepassageway comprises providing one or more heating elements within thepassageway; and impeding the flow of the inlet stream of gas within thepassageway comprises causing the inlet stream of gas to flow in adirection transverse to the heating elements. In an exemplaryembodiment, a heat transfer coefficient within the passageway rangesfrom about 12.3 to about 33 Btu/hr*ft²*° F. In an exemplary embodiment,an operating temperature of the heating elements ranges from about 757to about 1147° F. In an exemplary embodiment, a heat transfercoefficient within the passageway ranges from about 12.3 to about 33Btu/hr*ft²*° F.; and an operating temperature of the heating elementsranges from about 757 to about 1147° F.

A system for conditioning feed gas has been described that includesmeans for heating an inlet stream of gas within a passageway; and meansfor impeding the flow of the inlet stream of gas within the passagewayusing a plurality of baffle elements that are positioned in differentplanes. In an exemplary embodiment, means for heating the inlet streamof gas within the passageway comprises means for positioning a pluralityof heating elements within the passageway. In an exemplary embodiment,means for impeding the flow of the inlet stream of gas within thepassageway comprises means for constricting the flow of the inlet streamof gas proximate the heating elements within the passageway. In anexemplary embodiment, means for impeding the flow of the inlet stream ofgas within the passageway comprises means for constricting the flow ofthe inlet stream of gas within the passageway. In an exemplaryembodiment, means for impeding the flow of the inlet stream of gaswithin the passageway comprises means for creating a serpentine flow ofthe inlet stream of gas within the passageway. In an exemplaryembodiment, means for impeding the flow of the inlet stream of gaswithin the passageway further comprises means for constricting the flowof the inlet stream of gas proximate the heating elements within thepassageway. In an exemplary embodiment, the angular spacing between theplanes of the baffle elements ranges from about 15 to 75 degrees. In anexemplary embodiment, the lateral spacing of the baffle elements withinthe passageway ranges from intimate contact to about several times theinternal diameter of the passageway. In an exemplary embodiment, thesystem further includes means for shearing the flow of the inlet streamof gas within the passageway. In an exemplary embodiment, the systemfurther includes means for flowing the inlet stream of gas within thepassageway at an angle over one or more heating elements. In anexemplary embodiment, the system further includes means for mixing theinlet stream of gas within the passageway over one or more heatingelements. In an exemplary embodiment, means for heating the inlet streamof gas within the passageway comprises providing one or more heatingelements within the passageway; and wherein means for impeding the flowof the inlet stream of gas within the passageway comprises means forcausing the inlet stream of gas to flow in a direction transverse to theheating elements. In an exemplary embodiment, a heat transfercoefficient within the passageway ranges from about 12.3 to about 33Btu/hr*ft²*° F. In an exemplary embodiment, an operating temperature ofthe heating elements ranges from about 757 to about 1147° F. In anexemplary embodiment, a heat transfer coefficient within the passagewayranges from about 12.3 to about 33 Btu/hr*ft²*° F.; and an operatingtemperature of the heating elements ranges from about 757 to about 1147°F.

It is understood that variations may be made in the above withoutdeparting from the scope of the invention. While specific embodimentshave been shown and described, modifications can be made by one skilledin the art without departing from the spirit or teaching of thisinvention. The embodiments as described are exemplary only and are notlimiting. Many variations and modifications are possible and are withinthe scope of the invention. Furthermore, one or more aspects of theexemplary embodiments may be omitted or combined with one or moreaspects of the other exemplary embodiments. Accordingly, the scope ofprotection is not limited to the embodiments described, but is onlylimited by the claims that follow, the scope of which shall include allequivalents of the subject matter of the claims.

1. An apparatus for heating fluidic materials, comprising: an outerhousing that defines an inner chamber; an inner housing that defines aninner chamber that is positioned at least partially within the innerchamber of the outer housing, wherein an end of the inner chamber of theinner housing is adapted to be operably coupled to an outlet stream offluidic materials; one or more first heating elements positioned withinthe inner chamber of the outer housing; one or more second heatingelements positioned within the inner chamber of the inner housing; apassageway operably coupled to a lower end portion of the inner chamberof the outer housing and another end portion of the inner chamber of theinner housing for conveying fluidic materials therebetween; and a flowcontrol valve operably coupled to the passageway for controlling theflow of fluidic materials therethrough.
 2. The apparatus of claim 1,further comprising: at least one temperature sensor operably coupled tothe outlet stream of fluidic materials.
 3. The apparatus of claim 2,further comprising a controller operably coupled to the temperaturesensor.
 4. The apparatus of claim 3, wherein the controller is operablycoupled to the first and second heating elements.
 5. The apparatus ofclaim 4, wherein the controller is adapted to control the operation ofthe first and second heating elements as a function of an operatingtemperature signal generated by the temperature sensor.
 6. The apparatusof claim 1, further comprising a controller operably coupled to the flowcontrol valve.
 7. The apparatus of claim 6, wherein the controller isadapted to operate the flow control valve to control a level of fluidicmaterials within the inner chamber of the outer housing.
 8. Theapparatus of claim 1, further comprising: at least one temperaturesensor operably coupled to the outlet stream of fluidic materials; and acontroller operably coupled to the temperature sensor, the flow controlvalve and the first and second heating elements; wherein the controlleris adapted to: control the operation of the first and second heatingelements as a function of an operating temperature signal generated bythe temperature sensor; and operate the flow control valve to control alevel of fluidic materials within the inner chamber of the outerhousing.
 9. The apparatus of claim 1, further comprising: a plurality ofbaffle assemblies positioned within at least one of the inner chambersof the inner and outer housings, wherein each of the baffle assembliescomprise first and second baffle elements, positioned in differentplaces, that each define one or more passages; wherein one or more ofthe first and second heating elements extend through one or more of thepassages of the baffle assemblies.
 10. The apparatus of claim 9, whereinthe spacing of the baffle assemblies in a longitudinal direction rangesfrom about 2 to 60 inches.
 11. The apparatus of claim 10, wherein thespacing of the baffle assemblies in a longitudinal direction is aboutequal to the internal diameter of one or more of the inner and outerhousings.
 12. The apparatus of claim 9, wherein the internal diametersof the passageways of the first and second baffle elements are greaterthan the external diameters of the corresponding first and secondheating elements.
 13. The apparatus of claim 12, wherein the internaldiameters of the passageways of the first and second baffle elements areat least about 10% greater than the external diameters of thecorresponding first and second heating elements.
 14. The apparatus ofclaim 1, wherein the number of first and second heating elements rangesfrom about 3 to
 360. 15. The apparatus of claim 1, wherein the averagecenter to center spacing of the first and second heating elements rangesfrom about 1 to 5 inches.
 16. The apparatus of claim 9, wherein theoutside diameters of the first and second heating elements are about0.475 inches and the inside diameters of the corresponding passagewaysthrough the first and second baffle elements are about 1/16^(th) toabout ¼^(th) of an inch larger in diameter.
 17. The apparatus of claim9, wherein each of the first and second baffle elements comprise anouter peripheral arcuate portion that mates with at least one of theinner and outer housing and another outer peripheral portion that doesnot mate with at least one of the inner and outer housing.
 18. Theapparatus of claim 9, wherein the baffle assemblies and at least one ofthe inner and outer housing define a serpentine flow path for thepassage of fluidic materials therethrough.
 19. The apparatus of claim 9,wherein the angular spacing between the planes of the first and secondbaffle elements ranges from about 15 to 75 degrees.
 20. The apparatus ofclaim 9, wherein the lateral spacing of the baffle assemblies within atleast one of the inner and outer housing ranges from intimate contact toabout several times the internal diameter of at least one of the innerand outer housing.
 21. The apparatus of claim 9, wherein the baffleassemblies are adapted to shear the flow of fluidic materials within atleast one of the inner and outer housing.
 22. The apparatus of claim 9,wherein the baffle assemblies are adapted to cause the fluidic materialswithin at least one of the inner and outer housing to flow over at leastone of the first and second heating elements at an angle to at least oneof the first and second heating elements.
 23. The apparatus of claim 9,wherein the baffle assemblies are adapted to cause the fluidic materialswithin at least one of the inner and outer housing to mix over at leastone of the first and second heating elements at an angle to at least oneof the first and second heating elements.
 24. The apparatus of claim 9,wherein an operating temperature of at least one of the first and secondheating elements ranges from about 757 to about 1147° F.
 25. Theapparatus of claim 9, wherein a heat transfer coefficient within atleast one of the inner and outer housing ranges from about 12.3 to about33 Btu/hr*ft²*° F.; and wherein an operating temperature of at least oneof the first and second heating elements ranges from about 757 to about1147° F.
 26. The apparatus of claim 1, wherein the inner housing furtherdefines one or more drainage passages within a lower end portion; andfurther comprising a coalescing filter positioned within the innerchamber of the inner housing.
 27. A method for heating fluidicmaterials, comprising: within a common vessel, heating liquid materialswithin a lower portion of the common vessel using first immersionheaters and heating gaseous materials within an upper portion of thecommon vessel using second immersion heaters.
 28. The method of claim27, further comprising: controlling a level of liquid materials withinthe lower portion of the common vessel.
 29. The method of claim 27,wherein heating gaseous materials within the upper portion of the commonvessel comprises: heating gaseous materials within the upper portion ofthe common vessel within another vessel positioned within the upperportion of the common vessel.
 30. The method of claim 29, furthercomprising: coalescing liquids within the interior of the other vessel.31. The method of claim 30, further comprising: exhausting coalescedliquids out of the interior of the other vessel and into a lower endportion of the common vessel.
 32. The method of claim 27, furthercomprising: impeding the flow of materials within at least one of thecommon vessel and the other vessel using a plurality of baffle elementsthat are positioned in different planes.
 33. The method of claim 32,wherein impeding the flow of materials within at least one of the commonvessel and the other vessel using a plurality of baffle elements thatare positioned in different planes comprises constricting the flow ofthe materials proximate the heaters within at least one of the commonvessel and the other vessel.
 34. The method of claim 32, whereinimpeding the flow of the materials within at least one of the commonvessel and the other vessel comprises creating a serpentine flow of thematerials within at least one of the common vessel and the other vessel.35. The method of claim 32, wherein the angular spacing between theplanes of the baffle elements ranges from about 15 to 75 degrees. 36.The method of claim 32, wherein the lateral spacing of the baffleelements within at least one of the common vessel and the other vesselranges from intimate contact to about several times the internaldiameter of at least one of the common vessel and the other vessel. 37.The method of claim 32, further comprising: shearing the flow of thematerials within at least one of the common vessel and the other vessel.38. The method of claim 32, further comprising: flowing the materialswithin at least one of the common vessel and the other vessel at anangle over one or more heaters.
 39. The method of claim 32, furthercomprising: mixing the materials within at least one of the commonvessel and the other vessel over one or more heaters.
 40. The method ofclaim 32, wherein impeding the flow of materials within at least one ofthe common vessel and the other vessel comprises causing the materialswithin at least one of the common vessel and the other vessel to flow ina direction transverse to the heaters.
 41. The method of claim 32,wherein a heat transfer coefficient within at least one of the commonvessel and the other vessel ranges from about 12.3 to about 33Btu/hr*ft²*° F.
 42. The method of claim 32, wherein an operatingtemperature of the heaters ranges from about 757 to about 1147° F. 43.The method of claim 32, wherein a heat transfer coefficient within atleast one of the common vessel and the other vessel ranges from about12.3 to about 33 Btu/hr*ft²*° F.; and wherein an operating temperatureof the heaters ranges from about 757 to about 1147° F.
 44. Adistillation column assembly, comprising: a plurality of heatingassemblies operably coupled to one another, one or more of the heatingassemblies comprising: an outer housing that defines an inner chamber;an inner housing that defines an inner chamber that is positioned atleast partially within the inner chamber of the outer housing, whereinan end of the inner chamber of the inner housing is adapted to beoperably coupled to an outlet stream of fluidic materials; one or morefirst heating elements positioned within the inner chamber of the outerhousing; one or more second heating elements positioned within the innerchamber of the inner housing; a passageway operably coupled to a lowerend portion of the inner chamber of the outer housing and another endportion of the inner chamber of the inner housing for conveying fluidicmaterials therebetween; and a flow control valve operably coupled to thepassageway for controlling the flow of fluidic materials therethrough; areboiler assembly operably coupled to the plurality of heatingassemblies; and a condenser operably coupled to the plurality of heatingassemblies.
 45. A method of operating a distillation column assembly,comprising: within one or more common vessels, heating liquid materialswithin a lower portion of each of the common vessels using firstimmersion heaters and heating gaseous materials within an upper portionof one or more of the common vessels using second immersion heaters;condensing at least a portion of the gaseous materials; and reboiling atleast a portion of the liquid materials.